U.S. patent application number 10/188753 was filed with the patent office on 2003-02-06 for method for fixing toner.
Invention is credited to Emoto, Shigeru, Sugiyama, Tsunemi, Tanaka, Chiaki, Tomita, Masami, Watanabe, Kazuhito, Watanabe, Naohiro, Yamada, Hiroshi, Yamashita, Hiroshi.
Application Number | 20030027074 10/188753 |
Document ID | / |
Family ID | 19042668 |
Filed Date | 2003-02-06 |
United States Patent
Application |
20030027074 |
Kind Code |
A1 |
Emoto, Shigeru ; et
al. |
February 6, 2003 |
Method for fixing toner
Abstract
A method of fixing toner in a belt fixing unit having a fixing
roller; a heating roller; an endless fixing belt binding the
heating roller and the fixing roller under tension therebetween; a
pressure roller disposed to face the fixing roller intervening the
fixing belt; and a fixing heater disposed inside one of the
pressure roller and the heating roller, the method of fixing
includes: a step for fixing a toner image on an image fixing
material by conveying the toner image on the image fixing material
in between a portion of the fixing belt not touching the fixing
roller and the pressure roller; featured by the toner particle
being spherical having a roundness of 0.96 or more and contains a
colorant and resin component containing a modified polyester
resin.
Inventors: |
Emoto, Shigeru; (Shizuoka,
JP) ; Tanaka, Chiaki; (Shizuoka, JP) ;
Watanabe, Naohiro; (Shizuoka, JP) ; Yamada,
Hiroshi; (Shizuoka, JP) ; Sugiyama, Tsunemi;
(Shizuoka, JP) ; Yamashita, Hiroshi; (Shizuoka,
JP) ; Watanabe, Kazuhito; (Kanagawa, JP) ;
Tomita, Masami; (Shizuoka, JP) |
Correspondence
Address: |
OBLON SPIVAK MCCLELLAND MAIER & NEUSTADT PC
FOURTH FLOOR
1755 JEFFERSON DAVIS HIGHWAY
ARLINGTON
VA
22202
US
|
Family ID: |
19042668 |
Appl. No.: |
10/188753 |
Filed: |
July 5, 2002 |
Current U.S.
Class: |
430/124.1 ;
399/331; 430/108.4; 430/108.8; 430/109.4; 430/110.1;
430/137.17 |
Current CPC
Class: |
G03G 9/08795 20130101;
G03G 9/0827 20130101; G03G 9/0804 20130101; G03G 9/08764 20130101;
G03G 9/08755 20130101; G03G 9/0806 20130101; G03G 9/08782
20130101 |
Class at
Publication: |
430/124 ;
430/108.8; 430/110.1; 430/137.17; 430/108.4; 430/109.4;
399/331 |
International
Class: |
G03G 009/08 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 6, 2001 |
JP |
2001-206554 |
Claims
What is claimed is:
1. A method of fixing toner in a belt fixing unit having a fixing
roller; a heating roller; an endless fixing belt binding the
heating roller and the fixing roller under tension therebetween; a
pressure roller disposed to face the fixing roller intervening the
fixing belt; and a fixing heater disposed inside one of the
pressure roller and the heating roller, comprising: a step for
fixing a toner image on an image fixing material by conveying the
toner image on the image fixing material in between a portion of
the fixing belt not touching the fixing roller and the pressure
roller; wherein the toner particle is spherical having a roundness
of 0.96 or more and contains a colorant and resin component
containing a modified polyester resin.
2. A method for fixing toner according to claim 1, further
comprising: a second step for fixing the toner image on the image
fixing material by moving the portion of the fixing belt not
touching the fixing roller to touch the fixing roller and conveying
the toner image on the image fixing material in between the portion
of the fixing belt and the pressure roller; wherein a fixing
pressure exerted in between the fixing belt and the pressure roller
in the step for fixing is reduced to avoid causing wrinkles on the
image fixing material.
3. A method for fixing toner according to claim 2, wherein the
fixing pressure in the step for fixing is 1 kg/cm.sup.2 or less and
a fixing pressure in the second step for fixing is not lower than
the fixing pressure in the step for fixing.
4. A method for fixing toner according to claim 1, wherein the
heating roller is a heating roller of low heat capacity.
5. A method for fixing toner according to claim 1, wherein the
toner contains a releasing agent.
6. A method for fixing toner according to claim 5, wherein the
releasing agent is a wax having a melting point of 60 to
120.degree. C. and the toner contains 1 to 20% by weight of the
wax.
7. A method for fixing toner according to claim 6, wherein the wax
has a weight-average molecular weight of 400 to 5000 and an acid
value of 1 to 30 mg KOH/g.
8. A method for fixing toner according to claim 5, wherein the
releasing agent particles are relatively uniformly dispersed inside
the toner particles, and the toner particles each carrying at least
3 releasing agent particles therein account for 70% or more by
number of all the toner particles.
9. A method for fixing toner according to claim 5, wherein the
releasing agent particles each having a dispersed particle diameter
of 0.1 .mu.m to 2 .mu.m account for 70% or more by number of all
the releasing agent particles.
10. A method for fixing toner according to claim 5, wherein the
releasing agent particles are needle-wise dispersed inside the
toner particles, and the releasing agent particles having a maximum
diameter of 3 .mu.m or more do not exceed 5% by number of all the
releasing agent particles.
11. A method for fixing toner according to claim 10, wherein the
releasing agent particles are dispersed inside the toner particles
in a manner to orient a direction of the maximum diameter of each
releasing agent particle not in parallel relationship to a nearest
surface of the toner particle but is oriented toward the inside of
the toner particle or not exposed at the surface of the toner
particle.
12. A method for fixing toner according to claim 5, wherein the
releasing agent is vegetable wax having a molecular weight of 400
to 2500 and an acid value of 1 to 30 mg KOH/g.
13. A method for fixing toner according to claim 5, wherein the
releasing agent is ester wax and the needle penetration at
50.degree. C. into the toner particles with the releasing agent
dispersed is 3 or less.
14. A method for fixing toner according to claim 1, wherein the
toner is prepared by dissolving or dispersing a toner composition
that contains at least a modified polyester resin and a colorant,
in an organic solvent, followed by granulating the composition in
an aqueous medium.
15. A method for fixing toner according to claim 14, wherein the
toner composition further contains a releasing agent.
16. A method for fixing toner according to claim 1, wherein the
toner is prepared by dissolving or dispersing in an organic
solvent, a toner composition that contains at least a polyester
prepolymer and a colorant, granulating the toner composition in an
aqueous medium while forming an urea bond-having polyester in the
resulting toner particles, and by treated under polyaddition
reaction.
17. A method for fixing toner according to claim 16, wherein the
toner composition further contains a releasing agent.
18. A method for fixing toner according to claim 1, wherein the
toner further contains a non-modified polyester resin and the ratio
by weight of the modified polyester resin to the non-modified
polyester resin in the toner is 5/95 to 80/20.
19. A method for fixing toner according to claim 1, wherein the
resin component contains, in terms of molecular weight distribution
of the Tetrahydrofurane solubles contained in the resin component,
5% or less composition matters having 1000 or less molecular
weight.
20. A method for fixing toner according to claim 1, wherein the
resin component has a glass transition point of 55 to 70.degree.
C.
21. A method for fixing toner according to claim 1, wherein the
tetrahydrofuran insolubles in the resin component account for 1 to
15% of the resin component.
22. A method for fixing toner according to claim 1, wherein the
resin component is controlled to have a molecular weight peak of
tetrahydrofuran solubles appears in the range of 1000 to 30,000 in
terms of the molecular weight distribution of tetrahydrofuran
solubles in the resin component and the tetrahydrofuran-soluble
component having a molecular weight of 30,000 or more account for
1% or more in the soluble molecular weight distribution, and the
toner has a weight-average particle diameter of 3 to 10 .mu.m.
23. A method for fixing toner according to claim 1, wherein the
molecular weight distribution of tetrahydrofuran solubles in the
resin component is designed to have the number-average molecular
weight of the solubles ranging from 2000 to 15,000 and the ratio of
weight-average molecular weight/number-average molecular weight
thereof is 10.0 or less.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for fixing toner
for fixing toner onto a transfer material in image-forming devices
such as copiers, printers and facsimile machines. More precisely,
the present invention relates to a method for fixing toner for
fixing toner onto a transfer material, using a belt-like heating
medium.
[0003] 2. Description of the Related Art
[0004] In monochromatic image-forming devices such as ordinary
copiers, printers and facsimile machines, a latent image is formed
on an image-carrying medium such as a photoconductor drum or belt
in a latent image-forming unit, then the latent image is developed
in a developing unit to form a toner image, and the toner image is
thereafter transferred onto a transfer medium such as transfer
paper represented by plain paper, special paper and the like, and
fixed thereon in a fixing unit.
[0005] On the other hand, in color image-forming devices such as
color copiers, color printers and color facsimile machines, in
general plural latent images are formed on an image-carrying medium
such as a photoconductor drum or belt, then the latent images are
developed with toners of different colors in a developing unit to
form toner images of different colors, thereafter the toner images
of such different colors are transferred, as combined into a full
color image, onto a transfer medium such as transfer paper, and the
color image on the transfer medium is then fixed thereon in a
fixing unit.
[0006] With the recent trend in the art toward energy-saving and
compact devices, a fixing unit utilizing a belt-like heating medium
(hereinafter referred to as "belt fixing") has become widely
used.
[0007] The belt fixing unit of this type makes it possible to
extend the contact time of toner to the belt surface at the time of
toner fixing, enabling toner fixing at a lower temperature, while
toner fusion on the belt often proceeds excessively and leads to
offsetting caused by melted toner adhered to the belt surface. In
particular, offsetting tends to be caused with color toners since
the color toners are generally required to exhibit glossiness to
some extent for forming sufficiently transparent and high-quality
images, and accordingly, the molecular weight distribution curve of
the binder resin contained in the color toner is sharpened so that
the color toner may have a sharp melting property. As a result,
toner fusion at the time of image fixing proceeds, thereby causing
offsetting.
[0008] In addition, additives to toner and other components may
adhere to the belt-like heating medium, and the belt may be thereby
worn or cracked to cause hot offsetting. Also, the belt may be
thereby ruptured.
[0009] To solve the problems abovementioned, various proposals have
been made for improving fixing units and toners for
electrophotography.
[0010] On the other hand, oil is applied to fixing rollers in
fixing units for preventing offsetting. In color image-forming
devices, toners of different colors of low viscosity must be used
in obtaining images with high priority in glossiness and
transparency of the color, and it is indispensable to apply oil to
fixing rollers to prevent offsetting.
[0011] It is known to add a releasing material (to support fixing)
such as wax to toner for preventing offsetting in image fixing.
However, depending on the properties of the wax used, especially
when the wax added could not well disperse in toner, the wax will
separate from the surfaces of toner particles or will bleed out of
them in long-term use in developing units, and will stain the
surfaces of carrier particles in two-component developers to
thereby often worsen the charging properties of toner. In
one-component developers, the wax added to toner will adhere to
development rollers and to blades used for thinning toner layers,
and will therefore often obstruct uniform development with toner.
From the viewpoint of development, therefore, preferably an amount
of wax to be added to toner is as small as possible.
[0012] Known references relating to toner and fixing units are
mentioned below, and the structures in the related art disclosed
therein and the problems with them are discussed.
[0013] Japanese Patent Application Laid-Open (JP-A) No.
07-219274
[0014] Configuration:
[0015] A color toner which contains a pigment-dispersed resin
prepared by adding polyolefin wax and aqueous paste of pigment to a
resin solution for pigment dispersion followed by heating the
resulting mixture, and in which the SP value difference between the
binder resin and the pigment-dispersed resin is in the range of 1.5
to 0.5.
[0016] Problem:
[0017] This is to improve the dispersibilty of polyolefin wax in
the binder resin in the toner. However, the polyolefin wax is not
sufficiently effective for improving the offset resistance of the
toner.
[0018] Japanese Patent Application Laid-Open (JP-A) No.
07-311479
[0019] Configuration:
[0020] A fixing roller for use with the toner described in Japanese
Patent Application Laid-Open (JP-A) No. 07-219274, of which the
surface layer is an elastic layer coated with fluororesin.
[0021] Problems:
[0022] Same as above.
[0023] Japanese Patent Application Laid-Open (JP-A) No.
07-33903
[0024] Configuration:
[0025] A toner containing a polyester resin with no THF insolubles
having Mn in the range of 2500 to 3500 and Mw in the range of
50,000 to 300,000.
[0026] Problem:
[0027] This requires a large amount of fixing oil.
[0028] Japanese Patent Application Laid-Open (JP-A) No.
07-333904
[0029] Configuration:
[0030] A toner which contains wax and a polyester resin of which
the amount of THF insolubles contained therein is in the range of
15 to 40% and polyhydric alcohol component is specifically defined.
In the toner, a difference in refractive index between the binder
resin and the wax is specifically defined.
[0031] Problem:
[0032] Difficult to form glossy images due to a large amount of THF
insolubles contained in the toner.
[0033] Japanese Patent Application Laid-Open (JP-A) No.
08-50367
[0034] Configuration:
[0035] A wax-containing toner, in which the wax is an ester wax
having a peak value in the molecular weight range of 350 to 850 and
900 to 4000 and having Mn of 350 to 4000 and Mw of 200 to 4000.
[0036] Problem:
[0037] Merely by defining the property of the wax contained in the
toner should not achieve sufficient offset resistance of the
toner.
[0038] Japanese Patent Application Laid-Open (JP-A) No.
08-50368
[0039] Configuration:
[0040] A toner which contains an ester wax in which the content of
ester compounds having the same total number of carbon atoms is in
the range of 50 to 95% by weight The ester wax contains 3 to 40
parts of ester compounds with respect to 100 parts by weight of the
binder resin contained in the toner.
[0041] Problem:
[0042] Merely by defining the property of the wax contained in the
toner should not achieve sufficient offset resistance of the
toner.
[0043] Japanese Patent Application Laid-Open (JP-A) No.
03-39971
[0044] Configuration:
[0045] A color toner which contains a resin with no toluene
insolubles, in which the resin has a peak value in the molecular
weight range of 500 to 2000 and 10,000 to 100,000, and has Mw of
10,000 to 80,000 and Mn of 1500 to 8000 while satisfying
Mw/M>3.
[0046] Problem:
[0047] Sufficient offset resistance of the toner is not
attained.
[0048] Japanese Patent Application Laid-Open (JP-A) No.
04-57062
[0049] Configuration:
[0050] A color toner having a flow tester melt viscosity of
105(10.sub.5) poises and a softening point of 90 to 120.degree. C.,
which contains a resin having Mw of 15,000 to 50,000and Mn of 2000
to 10,000 while having Mw/Mn of 5 to 15.
[0051] Problem:
[0052] Sufficient offset resistance of the toner is not
attained.
[0053] Japanese Patent Application Laid-Open (JP-A) Nos. 06-318001
and 08-137306
[0054] Problem:
[0055] In the fixing units disclosed in these publications, the
toner images formed are kept exposed to preheating in the
atmosphere. In low-speed image forming, the units are effective for
improving the toner fixing and offset resistance, but in high-speed
image forming, they are ineffective. In these units, in addition,
the distance between the fixing belt B and the recording medium G
must be narrowed for getting the benefit of the preheating therein.
Thus, there is a need to provide countermeasure against risk of
non-fixed toner images rubbing the belt.
[0056] Japanese Patent Application Laid-Open (JP-A) No.
04-273279
[0057] Problem:
[0058] The fixing device disclosed in this publication comprises a
step for fixing in which a toner image is fixed onto transfer paper
via a belt, followed by a step for carrying the transferred image
on the belt and a step for releasing the toner image and the
transfer paper from the belt. In this device, therefore, the
transfer paper bearing a toner image in the step for fixing is kept
preheated by the belt, and, as a result, the toner on the transfer
paper tends to be excessively fused to cause offsetting. Moreover,
the temperature on the image-bearing surface of the transfer paper
tends to be uneven, and accordingly causes uneven image
glossiness.
[0059] Japanese Patent Application Laid-Open (JP-A) No.
11-44969
[0060] Problem:
[0061] This publication proposes a toner for electrophotography,
which contains a non-linear polyester binder resin and a releasing
agent. When used in low-speed processors, the toner exhibits good
fixing, glossiness and transparency, but in high-speed processors,
the toner is still not on a satisfactory level and needs further
improvement
SUMMARY OF THE INVENTION
[0062] In reviewing the problems abovementioned, the first object
of the present invention is to provide a method for fixing toner to
achieve good image quality, stable in actual use in terms of toner
fixing ability under low temperature, hot offsetting properties in
oil-less use, glossiness of color toner, and transparency of the
toner with use in OHP. The object is achieved by thorough
examination of the belt fixing unit introduced in the fixing
portion and by clarifying interactive properties and effective rage
of the interactive properties of the toners used in the method for
forming images which utilizes the fixing portion.
[0063] The second object of the present invention is to provide a
method for fixing toner for forming stable and high-quality toner
images on image fixing material (onto which images are fixed) which
effectively prevents rubbing of non-fixed images or wrinkles on the
image fixing materials, and which also allows smooth transportation
and fixing of image fixing materials specifically in high speed
fixing device or color image forming device.
[0064] The objects abovementioned can be attained by the aspects of
the present invention described hereinafter.
[0065] The first aspect of the method for fixing toner of the
present invention in a belt fixing unit having a fixing roller; a
heating roller; an endless fixing belt binding the heating roller
and the fixing roller under tension therebetween; a pressure roller
disposed to face the fixing roller intervening the fixing belt; and
a fixing heater disposed inside one of the pressure roller and the
heating roller, comprises: a step for fixing a toner image on an
image fixing material by conveying the toner image on the image
fixing material in between a portion of the fixing belt not
touching the fixing roller and the pressure roller; wherein the
toner particle is spherical having a roundness of 0.96 or more and
contains a colorant and resin component containing a modified
polyester resin.
[0066] The second aspect of the method for fixing toner according
to the first aspect further comprises, in addition to the step for
fixing in the first aspect, a second step for fixing the toner
image on the image fixing material by moving the portion of the
fixing belt not touching the fixing roller to touch the fixing
roller and conveying the toner image on the image fixing material
in between the portion of the fixing belt and the pressure roller;
wherein a pressure exerted in between the fixing belt and the
pressure roller in the step for fixing is reduced to avoid causing
wrinkles on the image fixing material.
[0067] The third aspect of the method for fixing toner according to
the second aspect is characterized in that the fixing pressure in
the step for fixing is 1 kg/cm.sup.2 or less and the fixing
pressure in the second step for fixing is not lower than the fixing
pressure of the step for fixing.
[0068] The fourth aspect of the method for fixing toner according
to the first aspect is characterized in that the heating roller is
a heating roller of low heat capacity.
[0069] The fifth aspect of the method for fixing toner according to
the first aspect is characterized in that the toner contains a
releasing agent.
[0070] The sixth aspect of the method for fixing toner according to
the fifth aspect is characterized in that the releasing agent is a
wax having a melting point of 60 to 120.degree. C. and the toner
contains 1 to 20% by weight of the wax.
[0071] The seventh aspect of the method for fixing toner according
to the sixth aspect is characterized in that the wax has a
weight-average molecular weight of 400 to 5000 and an acid value of
1 to 30 mg KOH/g.
[0072] The eighth aspect of the method for fixing toner according
to the fifth aspect is characterized in that the releasing agent
particles are relatively uniformly dispersed inside the toner
particles, and the toner particles each carrying at least 3
releasing agent particles therein account for 70% or more by number
of all the toner particles.
[0073] The ninth aspect of the method for fixing toner according to
the fifth aspect is characterized in that the releasing agent
particles each having a dispersed particle diameter of 0.1 .mu.m to
2 .mu.m account for 70% or more by number of all the releasing
agent particles.
[0074] The tenth aspect of the method for fixing toner according to
the fifth aspect is characterized in that the releasing agent
particles are needle-wise dispersed inside the toner particles, and
the releasing agent particles having a maximum major diameter of 3
.mu.m or more do not exceed 5% by number of all the releasing agent
particles.
[0075] The eleventh aspect of the method for fixing toner according
to the tenth aspect is characterized in that the releasing agent
particles are dispersed inside the toner particles in such a
controlled condition that the major diameter of each releasing
agent particle is not parallel to the toner particle surface but is
oriented toward the inside of the toner particle or is not exposed
at the surface of the toner surface.
[0076] The twelfth aspect of the method for fixing toner according
to the fifth aspect is characterized in that the releasing agent is
vegetable wax having a molecular weight of 400 to 2500 and an acid
value of 1 to 30 mg KOH/g.
[0077] The thirteenth aspect of the method for fixing toner
according to the fifth aspect is characterized in tat the releasing
agent is ester wax and the needle penetration at 50.degree. C. into
the toner particles with the releasing agent dispersed therein is 3
or less.
[0078] The fourteenth aspect of the method for fixing toner
according to the first aspect is characterized in that the toner is
prepared by dissolving or dispersing a toner composition that
contains at least a modified polyester resin and a colorant, in an
organic solvent followed by granulating the composition in an
aqueous medium.
[0079] The fifteenth aspect of the method for fixing toner
according to the fourteenth aspect is characterized in that the
toner composition further contains a releasing agent.
[0080] The sixteenth aspect of the method for fixing toner
according to the first aspect is characterized in that the toner is
prepared by dissolving or dispersing a toner composition that
contains at least a polyester prepolymer and a colorant, in an
organic solvent, followed by granulating the composition in an
aqueous medium while an urea bond-having polyester is formed in the
resulting toner particles and while the binder resin in the toner
particles being formed is subjected to polyaddition.
[0081] The seventeenth aspect of the method for fixing toner
according to the sixteenth aspect is characterized in that the
toner composition further contains a releasing agent.
[0082] The eighteenth aspect of the method for fixing toner
according to the first aspect is characterized in that the toner
further contains a non-modified polyester resin and the ratio by
weight of the modified polyester resin to the non-modified
polyester resin in the toner is 5/95 to 80/20.
[0083] The nineteenth aspect of the method for fixing toner
according to the first aspect is characterized in that the resin
component is so controlled that its tetrahydrofuran-soluble
component having a molecular weight of 1000 or less accounts for 5%
or less in the molecular weight distribution of tetrahydrofuran
solubles in the resin component.
[0084] The twentieth aspect of the method for fixing toner
according to the first aspect is characterized in that the resin
component has a glass transition point of 55 to 70.degree. C.
[0085] The twenty-first aspect of the method for fixing toner
according to the first aspect is characterized in that the
tetrahydrofuran insolubles in the resin component account for 1 to
15% of the resin component.
[0086] The twenty-second aspect of the method for fixing toner
according to the first aspect is characterized in that the resin
component is so controlled that a molecular weight peak of
tetrahydrofuran solubles appears in the range of 1000 to 30,000 in
the molecular weight distribution of tetrahydrofuran solubles in
the resin component and the tetrahydrofuran-soluble component
having a molecular weight of 30,000 or mope account for 1% or more
in the soluble molecular weight distribution, and the toner has a
weight-average particle diameter of 3 to 10 .mu.m.
[0087] The twenty-third aspect of the method for fixing toner
according to the first aspect is characterized in that the
molecular weight distribution of tetrahydrofuran solubles in the
resin component is arranged to have the number-average molecular
weight of the solubles ranging from 2000 to 15,000 and the ratio of
weight-average molecular weight/number-average molecular weight to
be 10.0 or less.
[0088] The first aspect of the present invention provides a method
for fixing toner rapidly and stably under high-speed processing or
color image-forming.
[0089] The second aspect of the present invention provides a method
for fixing toner according to the first aspect, which allows
forming of good images, satisfying toner fixing, and hot-offset
resistance in high-speed processors.
[0090] The third aspect of the present invention provides a method
for fixing toner according to the second aspect which allows smooth
transportation of the image fixing material without causing
wrinkles, and improving toner fixing in low-temperatures.
[0091] The fourth aspect of the present invention provides a method
for fixing toner according to the first aspect which shortens rise
time and saves energy, while maintaining toner fixing at low
temperatures.
[0092] The fifth aspect of the present invention provides a method
for fixing toner according to the first aspect, in which the toner
contains a releasing agent.
[0093] The sixth aspect of the present invention provides a method
for fixing toner according to the fifth aspect, used in oil-less
belt-fixing devices.
[0094] The seventh aspect of the present invention provides a
method for fixing toner according to the sixth aspect, which
exhibits releasability in a wide range of oil-less fixing.
[0095] The eighth aspect of the present invention provides a method
for fixing toner according to the fifth aspect, which improves
toner releasability and glossiness.
[0096] The ninth aspect of the present invention provides a method
for fixing toner according to the fifth aspect, which improves
transparency of a color toner.
[0097] The tenth aspect of the-present invention provides a method
for fixing toner according to the fifth aspect, which improves
toner fixing and glossiness.
[0098] The eleventh aspect of the present invention provides a
method for fixing toner according to the tenth aspect, which
improves toner flowability and charge stability.
[0099] The twelfth aspect of the present invention provides a
method for fixing toner according to the fifth aspect, which
improves toner fixing ability.
[0100] The thirteenth aspect of the present invention provides a
method for fixing toner according to the fifth aspect, which
improves fixing ability of a dry toner.
[0101] The fourteenth aspect of the present invention provides a
method for fixing toner according to the first aspect, which
improves fixing ability, glossiness and transparency of the
toner.
[0102] The fifteenth aspect of the present invention provides a
method for fixing toner according to the fourteenth aspect, which
improves toner releasability and glossiness.
[0103] The sixteenth aspect of the present invention provides a
method for fixing toner according to the first aspect, which
improves fixing ability, glossiness and transparency of a color
toner.
[0104] The eighteenth aspect of the present invention provides a
method for fixing toner according to the first aspect, which
improves fixing and charge stability of the toner.
[0105] The nineteenth aspect of the present invention provides a
method for fixing toner according to the first aspect, in which the
dry toner has satisfying heat resistance.
[0106] The twentieth aspect of the present invention provides a
method for fixing toner according to the first aspect, which
improves fixing ability of the toner.
[0107] The twenty-first aspect of the present invention provides a
method for fixing toner according to the first aspect, which
improves releasability of the toner.
[0108] The twenty-second aspect of the present invention provides a
method for fixing toner according to the first aspect, which
improves releasability of the toner.
[0109] The twenty-third aspect of the present invention provides a
method for fixing toner according to the first aspect, which
improves toner glossiness.
[0110] In addition, when the binder component in the toner is
controlled to contain THF-soluble content having a molecular weight
of 1000 or less accounts for 5% or less in the molecular weight
distribution of THF solubles in the binder component, or when the
polyester resin in the toner has a glass transition point of 55 to
75.degree. C. and has an acid value of 1 to 30 mg KOH/g, or when
the THF-insoluble content of the binder component in the toner is 1
to 15%, the toner may be stably fixed to produce good images. In
particular, the color toner forms glossy and transparent images
suitable for use in OHP.
[0111] Further, when the binder component in the toner is
controlled to have a molecular weight peak of THF solubles appears
in the range of 1000 to 30,000 in the molecular weight distribution
of THF solubles in the binder component and the THF-soluble content
having molecular weight of 30,000 or more account for 1% or more in
the soluble molecular weight distribution and the toner has a
weight-average particle diameter of 3 to 10 .mu.m, or when the
molecular weight distribution of THF solubles in the binder
component in the toner is arranged to have number-average molecular
weight of the solubles 2000 to 15,000 and the ratio of
weight-average molecular weight/number-average molecular weight at
10.0 or less, then a dry toner which covers a wide range of image
fixing is obtained.
[0112] Moreover, in the present invention, since the proportion of
wax existing on the surfaces of the toner particles can be reduced
and, in addition, wax is finely dispersed, the toner forms good
color images of high transparency. For these reasons, the toner of
the present invention allows designing of compact and inexpensive
color copiers and printers without a need to provide oils.
[0113] Furthermore, the toner forming method of the present
invention realized dispersion of a fine releasing agent inside the
toner particles which was unattained by conventional premix
grinding methods. In toner particles prepared through suspension
polymerization, wax is enclosed in the resin. Therefore, as
compared with ground toner, an effect of releasability of the toner
prepared by the suspension polymerization with respect to contained
amount of wax deteriorates. Still another advantage of the toner of
the present invention is that it can readily disperse even in a
polyester resin, which, however, could not be used as a binder
resin in ordinary polymerization to form toner. In addition, the
profile of the toner of the present invention is easy to control,
and showing favorable properties of the powdered toner. The present
invention has made it possible to form a toner having high transfer
efficiency.
[0114] According to the toner forming method of the present
invention, wax can be finely dispersed in the toner formed, as
compared with ground toner. In an ordinary method of grinding
toner, fine toner particles having a particle diameter of 4 to 6
.mu.m are substantially difficult to produce in view of the
productivity and the production costs. Despite of the situation,
the present invention has made it possible to easily produce such
fine toner particles. The unit size of wax particles to be
dispersed inside the toner particles in the present invention can
be reduced, and therefore, the toner particles can form color
images of higher quality, especially those of higher transparency
suitable for use in OHP. Combining the toner and the belt-fixing
device in the present invention solves the problems mentioned below
which was not solved in conventional oil-less belt-fixing
devices.
[0115] 1) As compared with roller fixing, the surface pressure in
belt fixing is difficult to increase, and the releasing agent is
hardly released from the toner in oil-less devices. Therefore, in
high-speed oil-less fixing, the releasability only covers a narrow
range.
[0116] 2) Since the surface pressure in belt fixing is low, the
color images formed has less glossiness.
[0117] 3) Since the nip width is broad in belt fixing, often causes
wrinkles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0118] FIG. 1 is a conceptual view showing a belt fixing unit for
use in the method for fixing toner of the present invention.
[0119] FIG. 2 is a partly exploded view of the belt fixing unit
shown in FIG. 1.
[0120] FIG. 3 is a conceptual view showing a hot roller fixing
unit
[0121] FIG. 4 is a GPC chromatogram of the toner prepared in
Example 1.
[0122] FIG. 5 is a cross-sectional view of the toner particle
prepared in Example 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0123] Belt Fixing Unit for Use in the Method for Fixing Toner of
the Present Invention
[0124] FIG. 1 shows one example of a belt fixing unit for use in
the method for fixing toner of the present invention; and FIG. 2 is
a partly exploded view of FIG. 1. The belt fixing unit illustrated
is for oil-less toner fixing in a color image-forming device, and
it is specifically designed to prevent hot-offsetting and shortened
rise time.
[0125] In FIG. 1 and FIG. 2, 1 indicates a heating roller, 2
indicates a fixing roller, 3 indicates an endless fixing belt, 4
indicates a pressure roller, 5 indicates a heater for heating the
fixing belt, 6 indicates an inlet guide plate, 7 indicates a
temperature monitoring means, 8 indicates a part of the fixing belt
for first fixing, 9 indicates a part of the fixing belt for second
fixing, 10 indicates a pressure unit with a pressure spring, 11
indicates a tension applicator with a tension spring, and 13
indicates transfer paper with unfixed toner 13a thereon.
[0126] The fixing belt 3 is laid along the heating roller 1 and the
fixing roller 2 under tension therebetween (to which a
predetermined tension is applied), and the pressure roller 4 is
disposed adjacent to the fixing roller 2 via the fixing belt 3. The
pressure roller 4 is pressed against the fixing roller 2 via the
fixing belt 3 in the part 9 for second fixing; but in the part 8
for first fixing, it is pressed against the fixing belt 3, not kept
in contact with the fixing roller 2.
[0127] The heating roller 1 with the heater 5 built therein is made
of a thin-wall met pipe (e.g., aluminum, iron, copper or stainless
steel pipe) having a small diameter and having a lowered heat
capacity, and it facilitates rapid rising of the device. The fixing
belt 3 is heated by the heater 5 via the heating roller 1, and the
temperature monitoring means 7 monitors the surface temperature of
the fixing belt 3 heated by the heating roller 1. Based on the
temperature signal from the temperature monitoring means 7, a
temperature controller (not shown) controls the heater 5 so that
the surface of the fixing belt 3 can be kept at a predetermined
temperature.
[0128] Driven by motors (not shown), the fixing roller 2, the
heating roller 1, the pressure roller 4 and the fixing belt 3 are
rotated. Transfer paper, a type of transfer material is conveyed to
run through the fixing belt 3 and the pressure roller 4, and the
toner image on the transfer paper is heated by the fixing belt 3
and fixed onto it In the part 8 for first fixing, the fixing
pressure (the pressure between the fixing belt 3 and the pressure
roller 4) is controlled low so as not to wrinkle the transfer paper
in the step for fixing; and in the part 9 for second fixing, the
fixing pressure (the contact pressure between the fixing belt 3 and
the pressure roller 4) is controlled to attain the intended fixing
in the second step for fixing.
[0129] The heating roller 1 is disposed movable, and this is
pressed by the pressure spring 10 to give a tension to the fixing
belt 3; and the pressure roller 4 is pressed by the pressure spring
10, and it presses the fixing roller 2 via the fixing belt 3. The
fixing pressure in the step for fixing is controlled by the tension
of the fixing belt 3 that is controlled by the tension spring 11,
while the fixing pressure in the second step for fixing is
controlled by the pressure spring 10. If desired, the pressure
spring 10 may be fitted to the fixing roller 2 to press it, whereby
the pressure roller 4 is pressed against the fig roller 2 via the
fixing belt 3.
[0130] In this device illustrated, the heater 5 heats the fixing
belt 3 via the heating roller 1 of low heat capacity, and the
device can rise in a moment In addition, in the device, the
distance for fixing is kept long sufficiently for the step for
fixing and the second step for fixing (that is, the nip width is
long, and therefore the nip time is very long, ranging from 50 is
to 200 ms), and the fixing belt 3 is self-coolable (that is, the
fixing belt 3 does not have a heat source around its surface with
an unfixed toner image thereon in the parts 8 and 9 for fixing, and
therefore the surface of the fixing belt 3 in those parts is
spontaneously cooled after toner fixing thereon). Accordingly, the
device ensures a good temperature range favorable for fixing, and
covers wide range of image fixing.
[0131] Moreover, since the fixing pressure in the step for fixing
in which the transfer paper first reaches the pressure roller 4 is
kept satisfactorily low, for example, it is 0.5 kg/cm.sup.2 or
less, preferably 0.2 kg/cm.sup.2 or less, the transfer paper can
smoothly enter the nip area for fixing between the fixing belt 3
and the pressure roller 4, and therefore, the frequency of wrinkles
of the transfer paper can be reduced to be not higher than that in
conventional devices (tat is, the frequency of wrinkles of the
transfer paper is not higher than that in hot roller fixing
devices).
[0132] The fixing device to be used in carrying out the method for
fixing toner of the present invention is a belt fixing device as
illustrated herein, of which the basic configuration comprises the
fixing roller 2, the heating roller 1, the endless fixing belt 3 of
low heat capacity laid along the heating roller 1 and the fixing
roller 2 under tension therebetween, and the pressure roller 4
disposed adjacent to the fixing roller 2 via the fixing belt 3.
[0133] The heating roller 1 has the heater 5 installed inside it
for heating the fixing belt. For reducing its heat capacity, the
heating roller 1 is preferably made from a material of low specific
heat and high heat conductivity, for which, for example, preferred
is metal such as aluminum, copper, iron or stainless steel.
[0134] The fixing belt 3 is heated by the heater 5 via the heating
roller 1. For improving the thermal responsibility of the fixing
belt and for ensuring the flexibility thereof, it is desirable that
the thickness of the belt base is 30 to 150 .mu.m, for which, for
example, preferred is nickel or polyimide. Also for improving the
thermal responsibility of the fixing belt, the release layer of the
fixing belt 3 may be made of silicone rubber preferably having a
thickness of 50 to 300 .mu.m, or fluororesin preferably having a
thickness of 10 to 50 .mu.m.
[0135] The temperature monitoring means 7 is to monitor the surface
temperature of the fixing belt 3 heated by the heating roller 1.
Based on the temperature signal from the thermistor 7, a
temperature controller (not shown) controls the heater 5 so that
the surface of the fixing belt 3 can be kept at a predetermined
temperature.
[0136] Driven by motors (not shown), the fixing roller 2, the
heating roller 1, the fixing belt 3 and the pressure roller 4 are
rotated. Transfer paper, a type of transfer material is conveyed in
the direction of the illustrated arrow to run through the nip area
for fixing between the fixing belt 3 and the pressure roller 4, and
the toner image on the transfer paper is heated by the fixing belt
3 and fixed onto it
[0137] Because of the configuration of the device, the heating
roller does not require any specific large load. The force
necessary for laying the fixing belt 3 along the two rollers under
tension therebetween may be 1 kgf (9.8 N)/one roller, under which
the fixing belt 3 functions satisfactorily; Since the heating
roller 1 for heating the fixing belt is spaced from the nip area
for fixing, the heating roller 1 does not require fixing pressure
and therefore does not receive any large load. Accordingly, the
heating roller 1 can be down-sized and thin-walled, and its heat
capacity can be reduced. This shortens the rise time of the
device.
[0138] The heat capacity of the heating roller 1 of low heat
capacity is preferably 45 cal/.degree. C. or less, more preferably
15 cal/.degree. C. or less.
[0139] Comparison Between Belt Fixing Device and Hot Roller Fixing
Device
[0140] The belt fixing device to be used in the method for fixing
toner of the present invention is compared with a hot roller fixing
device. Both in the belt fixing device and in the hot roller
heating device, the lowermost temperature for toner fixing lowers
to the same degree with the increase in the nip time, and the belt
fixing is preferred to the hot roller fixing since the contact time
of the fixing belt with the toner surface can be prolonged in the
former. In the hot roller fixing device, the nip width of the
fixing roller can be broadened. En this respect, the belt fixing
device will be inferior to the hot roller fixing device because of
the belt conveyor mechanism of the former in which the nip width is
difficult to broaden. Therefore, when the belt fixing device is
driven in an oil-less condition, the nip pressure is often
insufficient for releasing the releasing agent from the toner to
prevent offset, and as a result, the offset temperature will be
often low.
[0141] Especially in high-speed oil-less processors, the
requirements of both high-speed fixing and hot-offset resistance
must be satisfied, and the fixing unit for such high-speed oil-less
processors must be economical to save energy. Given that situation,
it is desired to further improve the properties of toner than
before in order to obtain an advanced toner that is well usable in
any oil-less processors and has the advantages of good
releasability and broad latitude in fixing. We, the present
inventors have found a novel toner suitable to the method for
fixing toner of the present invention, and the novel toner is
described hereinafter.
[0142] Toner of the Present Invention
[0143] The toner suitable for the method for fixing toner of the
present invention is a dry toner comprising a resin and a colorant,
and the resin contains a modified polyester resin. Preferably, in
the toner, the content of the polyester resin including a modified
polyester resin is the highest of all the resin component
therein.
[0144] The toner may be prepared by dissolving or dispersing a
toner composition in an organic solvent followed by granulating the
composition in an aqueous medium while the binder resin in the
toner particles being formed is subjected to polyaddition; or by
dissolving or dispersing a toner composition that contains a
prepolymer, in an organic solvent, followed by granulating the
composition in an aqueous medium while an urea bond-having
polyester is formed in the resulting toner particles and while the
binder resin in the toner particles being formed is subjected to
polyaddition. Thus prepared, the toner satisfies the requirements
of good fixing and hot-offset resistance. When the toner is used in
oil-less belt fixing devices, a releasing agent is added hereto. If
desired, the toner may also contain a charge-controlling agent that
will be mentioned hereinunder. The amount of the charge-controlling
agent may be 0.1 to 5%, by which the charge level of the toner can
be controlled.
[0145] In many cases, wax is used for the releasing agent which,
however, is not limited thereto. The releasing agent to be in the
toner my be any and every material of releasing ability. The
oil-less fixing device for use herein is not limited to a
completely oil-less one but oil may be infiltrated into the
rollers. In this case, even a small amount of wax will be
effective.
[0146] Of various dry toners, especially full-color toners are
required to have the basic characteristics of thermal storability,
low-temperature fixing ability and hot-offset resistance and
additional characteristics of color reproducibility, transparency
and glossiness that are contradictory to the basic characteristics.
To realize all these characteristics, the matters indispensable to
full-color toners are that the colorant and wax must well disperse
in them (for good color reproducibility and transparency) and the
resin in the toners must have a sharp molecular weight distribution
(for good transparency and glossiness), and, in addition, the
toners must further satisfy the requirements of low-temperature
fixing and hot-offset resistance. In this respect, since the toner
of the present invention can be prepared through granulation in
water, polyester can be used in preparing the toner particles.
Therefore, the granulation method is favorable for preparing the
toner of the present invention that has well-balanced fixing
ability and offset resistance.
[0147] The toner of the present invention may contain a polyester
having a polar group with an urea bond, and the pigment therein
readily adsorbs the polyester at its urea bond moiety. Therefore,
the toner of the type is characterized by its ability to well
disperse the pigment therein. On the other hand, the urea bond
moiety in the polyester serves for negative adsorption against wax
in the toner, therefore repelling wax in the interface between the
polyester and wax. Another effect of the polyester in the toner is
that it stably disperses wax of low polarity in the toner. In
addition, the major part of the resin in the toner is a low
molecular component having a molecular weight of 30,000 or less,
and the resin in the toner is controlled to have a sharp molecular
weight distribution. Accordingly, the toner of the present
invention satisfies not only good glossiness and transparency but
also low-temperature fixing ability.
[0148] For hot-offset resistance of toner, various studies have
heretofore been made to control the molecular weight distibution of
the binder resin in toner. For example, for satisfying the two
contradictory requirements of low-temperature fixing ability and
hot-offset resistance of toner, a binder resin having a broad
molecular weight distribution is added to toner; or a resin mixture
of a high-molecular component having a molecular weight of from
hundreds of thousands to millions and a low-molecular component
having a molecular weight of from thousands to tens of thousands,
therefore having two molecular weight peaks or more in its
molecular weight distribution is added to toner so that the two
resin components thus in the toner may individually exhibit their
own functions in the toner. Of the resin mixture, the
high-molecular component is more effective against hot offsetting
when it has a crosslinked structure or it is gelled.
[0149] However, since full-color toner is required to form glossy
or transparent images, adding a large amount of such a
high-molecular resin component thereto is unfavorable. In the toner
of the present invention, the molecular weight of the polyester can
be enlarged through chain extension at the urea bond. Therefore,
the toner of the present invention attains good hot-offset
resistance while satisfying the requirements of transparency and
glossiness.
[0150] In the present invention, a toner composition is granulated
in an aqueous medium, and the binder resin in the toner particles
being formed is subjected to polycondensation. Here, a method of
GPC measurement will be described. The column is stabilized in a
heat chamber at 40.degree. C. and into the column under this
temperature, THF (tetrahydrofuran) as solvent is led to flow in at
a flow rate of 1 ml/min, and sample THF solution of the resin
adjusted to sample concentration of 0.05 to 0.6% by weight is
injected in the amount of 50 to 200 .mu.l, and measured. The
molecular weight of the sample is calculated from the relationship
between the logarithmic value of the calibration curve of a
standard sample, monodispersed polystyrene and the retention time
of the sample in the columns. The calibration curve is prepared,
using a polystyrene standard sample. The standard sample,
monodispersed polystyrene is, for example, a commercial product
from Tosoh Corporation, having a molecular weight of
2.7.times.10.sup.2 to 6.2.times.10.sup.6. The detector is a
refractive index (RI) detector. The columns are, for example,
combinations of TSKgel G1000H, G2000H, G2500H, G3000H, G4000H,
G5000H, G6000H, G7000H and GMH, all of which are available from
Tosoh Corporation.
[0151] The main peak molecular weight of the binder resin generally
is 1000 to 30,000, preferably 1500 to 10,000, more preferably 2000
to 8000. If the component having a molecular weight of lower than
1000 increases in the binder resin, the thermal storability of the
toner containing the binder resin will become low; and if the
component having a molecular weight of not lower than 30,000
increases, the low-temperature fixing ability of the toner
generally lowers. However, it will be possible to prevent as much
as possible the reduction in the low-temperature fixing ability of
the toner by controlling the molecular weight balance of the binder
resin. The content of the resin component having a molecular weight
of 30,000 or more in the toner may be 1% or more, but preferably 3
to 6% though depending on the other components of the toner. If the
content of the high-molecular resin component is smaller than 1%,
the hot-offset resistance of the toner will become low; but if
larger than 10%, the glossiness and the transparency of the toner
will become low.
[0152] Preferably, Mn of the binder resin is 2000 to 15,000, and
the ratio Mw/Mn thereof is 10 or less. If the ratio Mw/Mn is higher
than 10, the microscopic miscibility of the resin will become low
and the glossiness of the toner will therefore lower. Resin having
Mn of smaller than 2000 will cause a problem in that, depending on
the dispersant used along with it, the low-molecular component of
the resin will contaminate the toner carrier. Resin having Mn
exceeding 15,000 will increase the oily viscosity of the toner
slurry being produced, and the colorant could not well disperse in
the toner slurry. If so, when a color toner is prepared, its color
reproducibility will be poor. For improving the releasing ability
of the colorant, the amount of the releasing agent to be in the
toner may be reduced, and in place of it, the binder resin to be in
the toner may be so formed that it contains 1 to 15% of THF
insolubles. In this case, the hot-offset resistance of the toner
may be improved. When wax is used for the releasing agent, the
releasing ability of the toner will increase, but its disadvantage
is that too much wax will bleed out on the surfaces of the toner
particles, and the flowability of the toner will become low. In
this embodiment, the charge stability of the toner will become low
in one case, or wax will adhere to the toner carrier to lower the
durability of the toner carrier in another case. In these cases, if
the amount of the releasing agent in the toner is well balanced
with the other components of the toner, the THF insolubles in the
binder resin will act to improve the releasing ability of he toner.
The method of measuring the THF insolubles in the binder resin is
described below.
[0153] Method of Measuring THF Insolubles in Binder Resin
[0154] About 1.0 g (A) of the binder resin or the toner is sampled,
and its weight is measured.
[0155] About 50 g of THF is added to it, and kept at 20.degree. C.
for 24 hours.
[0156] This is first centrifuged, and then filtered through filter
paper for quantification, JIS Standard (P3801), 5-C.
[0157] The resulting filtrate is dried in vacuum to remove the
solvents and the amount of the residue of resin alone (B) is
measured.
[0158] This residue is the THF solubles.
[0159] The amount of the THF insolubles (%) in the binder resin in
the toner is obtained according to the following equation.
Amount of THF insolubles (%)=(A-B)/A.times.100
[0160] In case where the toner is sampled and analyzed for the THF
insolubles in the binder resin, the amount of the THF insolubles
except resin (W1) in the toner and the amount of the THF solubles
except resin (W2) are separately determined in known methods, and
the THF insolubles in the binder resin in the toner is obtained
according to the following equation.
Amount of THF insolubles (%)=(A-B-W2)/(A-W1-W2).times.100
[0161] Method of Preparing the Toner of the Present Invention
[0162] Next described is the method of preparing the toner of the
present invention.
[0163] The toner is prepared by dissolving or dispersing a toner
composition that contains at least a polyester resin or modified
polyester resin and a colorant and optionally contains a releasing
agent, in an organic solvent, followed by granulating the
composition in an aqueous medium. Alternatively, a polyester (i)
modified with urea bonds may be used for preparing the toner, for
which the polyester is subjected to polyaddition while the toner
composition containing it is granulated.
[0164] The modified polyester resin is meant to indicate polyester
resins with any other bonding group than ester bonds therein, or
those with any other resin component of different structures
covalent-bonded or ion-bonded thereto. For example, such modified
polyester resins are prepared by reacting the polyester terminals
with any others than ester bonds. Concretely, they are prepared by
introducing a functional group such as an isocyanate group capable
of reacting with an acid group or a hydroxyl group into the
terminals of a polyester resin followed by further reacting with an
active hydrogen compound to thereby modify the terminals of the
polyester resin. Examples of the modified polyester resin are
reaction products of an isocyanate group-having polyester
prepolymer (A) and an amine (B).
[0165] One example of the compound having plural active hydrogen
groups is prepared by bonding plural polyesters at their terminals,
and it includes, for example, urea-modified polyesters and
urethane-modified polyesters.
[0166] Another example of the resin is prepared by introducing a
reactive group with a double bond into the backbone chain of a
polyester followed by further introducing thereinto a graft
component bonding to the side chains thereof via a carbon-carbon
bond through radical polymerization at the reactive group, and it
includes, for example, styrene-modified polyesters and
acryl-modified polyesters.
[0167] Still another example of the resin is prepared by
copolymerizing a polyester at the backbone chain thereof with a
resin component of a different structure, for example, with a
silicone resin modified with any of a carboxyl group, a hydroxyl
group, an epoxy group or a mercapto group at its terminals, and it
includes, for example, silicone-modified polyesters.
[0168] The isocyanate group-having polyester prepolymer (A)
includes those prepared through reaction of an active hydrogen
group-having polycondensate polyester of a polyol (1) and a
polycarboxylic acid (2), with a polyisocyanate (3) The active
hydrogen group which the polyester possesses includes, for example,
a hydroxyl group (including an alcoholic hydroxyl group and a
phenolic hydroxyl group), an amino group, a carboxyl group and a
mercapto group. Of those, preferred is an alcoholic hydroxyl
group.
[0169] The polyol (1) includes diols (1-1) and tri- and other
higher polyols (1-2). (1-1) may be preferably used either alone or
in combination. Diols (1-1) include, for example, alkylene glycols
(e.g., ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol,
1,4-butanediol, 1,6-hexanediol); alkylene ether glycols (e.g.,
diethylene glycol, triethylene glycol, dipropylene glycol,
polyethylene glycol, polypropylene glycol, polytetramethylene ether
glycol); alicyclic diols (e.g., 1,4-cyclohexanedimetnanol,
hydrogenated bisphenol A); bisphenols (e.g., bisphenol A, bisphenol
F, bisphenol S); adducts of alkylene oxides (e.g., ethylene oxide,
propylene oxide, butylene oxide) to the alicyclic diols; and
adducts of alkylene oxides (e.g., ethylene oxide, propylene oxide,
butylene oxide) to the bisphenols. Of those, preferred are
alkylene-glycols having 2 to 12 carbon atoms, and alkylene oxide
adducts to bisphenols; and more preferred are alkylene oxide
adducts to bisphenols combined with alkylene glycols having 2 to 12
carbon atoms. Tri- and other higher polyols (1-2) include, for
example, trihydric to octahydric and other polyhydric aliphatic
alcohols (e.g., glycerin, trimethylolethane, trimethylolpropane,
pentaerythritol, sorbitol); trihydric and other polyhydric phenols
(e.g., trisphenol PA, phenol-novolak, cresol-novolak); and alkylene
oxide adducts to the trihydric and other polyhydric phenols.
[0170] The polycarboxylic acid (2) includes dicarboxylic acids
(2-1) and trihydric and other polyhydric carboxylic acids (2-2).
(2-1) may be preferably used either alone or in combination.
Dicarboxylic acids (2-1) include, for example, alkylenedicarboxylic
acids (e.g., succinic acid, adipic acid, sebacic acid);
alkenylenedicarboxylic acids (e.g., maleic acid, fumaric acid); and
aromatic dicarboxylic acids (e.g., phthalic acid, isophthalic acid,
terephthalic acid, naphthalenedicarboxylic acid). Of those,
preferred are alkenylenedicarboxylic acids having 4 to 20 carbon
atoms, and aromatic dicarboxylic acids having 8 to 20 carbon atoms.
Trihydric and other polyhydric carboxylic acids (2-2) include, for
example, aromatic polycarboxylic acids having 9 to 20 carbon atoms
(e.g., trimellitic acid, pyromellitic acid). If desired, anhydrides
or lower alkyl esters (e.g., methyl esters, ethyl esters, isopropyl
esters) of polycarboxylic acids (2) such as those mentioned above
may be reacted with polyols (1).
[0171] The ratio, of the polyol (1) the polycarboxylic acid (2)
represented in terms of equivalent ratio of the hydroxyl group [OH]
to the carboxyl group [COOH], defined by [OH]/[COOH] falls within
the range of 2/1 to 1/1, preferably 1.5/1 to 1/1, and more
preferably 1.3/1 to 1.02/1.
[0172] The polyisocyanate (3) includes, for example, aliphatic
polyisocyanates (e.g., tetramethylene diisocyanate, hexamethylene
diisocyanate, 2,6-diisocyanatomethyl caproate); alicyclic
polyisocyanates (e.g., isophorone diisocyanate, cyclohexylmethane
diisocyanate); aromatic diisocyanates (e.g., tolylene diisocyanate,
diphenylmethane diisocyanate); araliphatic diisocyanates (e.g.,
.alpha.,.alpha.,.alpha.',- .alpha.'-tetramethylxylylene
diisocyanate); isocyanurates; the polyisocyanates blocked with any
of phenol derivatives, oximes or caprolactams; and mixtures of two
more of these.
[0173] The ratio of the polyisocyanate (3) to the polyester to be
reacted with it is generally 5/1 to 1/1, preferably 4/1 to 1.2/1,
more preferably 2.5/1 to 1.5/1, in of the equivalent ratio of the
isocyanate group [NCO] of the former to the hydroxyl group [OH] of
the latter having a hydroxyl group, [NCO]/[OH]. If the ratio of
[NCO]/[OH is larger than 5, the low-temperature fixing ability of
the toner containing the binder resin will become low. On the other
hand, if the molar ratio of [NCO] is smaller than 1, the urea
content of the modified polyester lowers, and, as a result, the
hot-offset resistance of the toner will become low. The content of
the constitutive component, polyisocyanate (3) in the prepolymer
(A) terminated with an isocyanate group, is generally 0.5 to 40% by
weight, preferably 1 to 30% by weight, more preferably 2 to 20% by
weight. If the content is smaller than 0.5% by weight, the
hot-offset resistance of the toner will become low and, in
addition, both the thermal storability and the low-temperature
fixing ability of the toner will also lower On the other hand, if
the content is larger than 40% by weight, the low-temperature
fixing ability of the toner will become low.
[0174] The number of the isocyanate groups in one molecule of the
isocyanate group-having prepolymer (A) is generally at least one,
preferably 1.5 to 3, more preferably 1.8 to 2.5 in average. If it
is smaller than 1 in one molecule, the molecular weight of the
urea-modified polyester will increase, and the isocyanate
group-having prepolymer will be ineffective for improving the
hot-offset resistance of the toner.
[0175] The amines (B) are, for example, diamines (B1), trihydric
and other polyhydric amines (B2), aminoalcohols (B3),
aminomercaptans (B4), amino acids (55), and blocked amines (B6)
prepared by blocking the amino group in B1 to B5. Diamines (B1)
include, for example, aromatic diamines (e.g., phenylenediamine,
diethyltoluenediamine, 4,4'-diaminodiphenylmethane); alicyclic
diamines (e.g., 4,4'-diamino-3,3'-dimethyldicyclohexylmethane,
diaminecyclohexane, isophoronediamine); and aliphatic dines (e.g.,
ethylenediamine, tetramethylenediamine, hexamethylenediamine).
Trihydric and other polyhydric amines (B2) include, for example,
diethylenetriamine, triethylenetetramine. Aminoalcohols (B3)
include, for example, ethanolamine and hydroxyethylaniline.
Aminomercaptans (B4) include, for example, aminoethylmercaptan and
aminopropylmercaptan. Amino acids (B5) include, for example,
amninopropionic acid and aminocaproic acid. Blocked amines (B6)
prepared by blocking the amino group in B1 to B5 include, for
example, ketimine compounds and oxazoline compounds obtained from
amines of B1 to B5 mentioned above and ketones (e.g., acetone,
methyl ethyl ketone, methyl isobutyl ketone). Of those amines (B),
preferred are B1, and mixtures of B1 with minor B2.
[0176] If desired, the molecular weight of the urea-modified
polyesters may be controlled with a chain extension stopper. The
chain extension stopper includes, for example, monoamines (e.g.,
diethylamine, dibutylamine, butylamine, laurylamine), and their
blocked derivatives (e.g., ketimine compounds).
[0177] Regarding the ratio of the amine (B) to the isocyanate
group-having prepolymer (A) to be reacted with it, the equivalent
ratio of the isocyanate group [NCO] in the prepolymer (A) to the
amino group [NHx] in the amine (B), [NCO]/[NHx] is generally 1/2 to
2/1, preferably 1.5/1 to 1/1.5, more preferably 1.2/1 to 1/1.2. If
[NCO]/[NHx] is larger than 2 or smaller than 1/2, the molecular
weight of the urea-modified polyester (i) decreases, and, as a
result, the hot-offset resistance of the toner will become low. In
the present invention, the urea bond-modified polyester (i) may
have an urethane bond in addition to the urea bond. The molar ratio
of the urea bond content of the polymer to the urethane bond
content thereof is generally 100/0 to 10/90, preferably 80/20 to
20/80, more preferably 60/40 to 30/70. If the molar ratio of the
urea bond content of the polymer is smaller than 10%, the
hot-offset resistance of the toner will become low.
[0178] In the present invention, the toner binder may be the urea
bond-modified polyester (i) alone or may be a mixture of (i) with
any other non-modified polyester (ii). The combination of (i) and
(ii) is preferred to (i) alone, since it is effective for improving
the low-temperature fixing ability of toner, especially the
glossiness of color toner for use in full-color processors. (ii)
includes, for example, polycondensates of polyols (1) and
polycarboxylic acids (2) such as those in the polyester component
(i). The preferred examples of (ii) are those mentioned above for
(i). (ii) is not limited to non-modified polyesters only, and may
include polyesters modified with any other chemical bond than urea
bonds, for example, those modified with urethane bonds.
[0179] It is desirable that (i) and (ii) are at least partly
miscible with each other in view of the low-temperature fixing
ability and the hot-offset resistance of the toner containing them.
Accordingly, it is desirable that the polyester components (i) and
(ii) are similar to each other in terms of their polyester
structures. In case where (i) is combined with (ii), the weight
ratio of (i) to (ii) is generally 5/95 to 80/20, preferably 5/95 to
30/70, more preferably 5/95. to 25/75, even more preferably 7/93 to
20/80. If the weight ratio of (i) is smaller than 5%, the
hot-offset resistance of the toner will become low, and, in
addition, both the thermal storability and the low-temperature
fixing ability of the toner will also lower.
[0180] Preferably, the hydroxyl value of (ii) is 5 or more, more
preferably 10 to 120, even more preferably 20 to 80. If it is
smaller than 5, the thermal storability and the low-temperature
fixing ability of the toner will become low. The acid value of (ii)
is generally 1 to 30, preferably 5 to 20. Having the defined acid
value, (ii) will negatively charge the toner.
[0181] In the present invention, the toner binder has a glass
transition point (Tg) generally ranging from 55 to 75.degree. C.,
preferably from 55 to 65.degree. C. If Tg of the toner binder is
lower than 55.degree. C., the thermal storability of the toner will
become low; but if higher than 75.degree. C., the low-temperature
fixing ability thereof will become low. Containing the
urea-modified polyester resin, the thermal storability of the dry
toner of the present invention is good even though the glass
transition point thereof is low, as compared with known polyester
toners.
[0182] The glass transition point (Tg) of the resin is measured
with SEIKO EXSTAR6000TG/DTA6200. Concretely, the resin is heated at
a rate of 10.degree. C./min up to 200.degree. C., and after one
thermal history, its glass transition point is measured.
[0183] Releasing Agent:
[0184] Wax in the toner of the present invention is preferably a
low-melting-point wax of which the melting point is 60 to
120.degree. C. Wax of the type well disperses in the binder resin
in the toner and serves more effectively as a releasing agent in
the interface between fixing rollers and the toner, and, as a
result, the toner exhibits good hot-offset resistance even though
any external releasing agent such as oil is not applied to fixing
rollers.
[0185] Wax having a melting point of higher than 120.degree. C. is
unfavorable since its lubricating effect is not good; and wax
having a melting point of lower than 60.degree. C. is also
unfavorable since it worsens the storability and the blocking
resistance of the toner. The melting point of wax for use in the
present invention is indicated by the maximum endothermic peak
thereof in differential scanning calorimetry (DSC).
[0186] For the wax component that functions as the releasing agent
in the present invention, usable are the following materials.
Concretely, the releasing agent for use herein includes tallows and
waxes, for example, vegetable waxes such as carnauba wax, cotton
wax, Japan wax, rice wax; animal waxes such as beeswax, lanolin;
mineral waxes such as ozokerite; and petroleum waxes such as
paraffin wax, microcrystalline wax, petrolatum. Apart from these
natural waxes, also usable herein are synthetic hydrocarbon waxes
such as Fisher-Tropsch wax, polyethylene wax; and other synthetic
waxes such as esters, ketones, ethers. Further usable are aliphatic
amides such as 12-hydroxystearaide, stearamide, anhydrous
phthalimide, aliphatic amides having chlorohydrocarbon groups; as
well as crystalline polymers having long alkyl branches, for
example, low-molecular crystalline polymer resins such as
polyacrylate homopolymers (e.g., poly-n-stearyl methacrylate,
poly-n-lauryl methacrylate) and copolymers (e.g., n-stearyl
acrylate-ethyl methacrylate copolymers).
[0187] Of those, vegetable waxes having Mw of 400 to 5000 and an
acid value of 1 to 30 are favorable to color toners, since they
suitably disperse in polyester resins to form fine transparent
particles favorable for color toners. Ester waxes into which the
needle penetration is 3 or les are also suitable to color toners,
as they are colorless and odorless by themselves. In general, color
toners for use in OHP must be transparent for image presentation
through OHP sheets. If the needle penetration into color toners is
larger than 3, the color toner fixing ability is not good.
[0188] The needle penetration into toner is an index of the thermal
storability of toner, and it is measured according to the test
method mentioned below.
[0189] Test Method for Thermal Storage:
[0190] 10 g of toner to be tested is put into a glass bottle having
an inner diameter of 25 mm and a height of 70 mm, and this is kept
in a thermostat at 50.degree. C. for 24 hours. After thus stored,
the needle penetration into the toner is measured with a
penetrometer of JIS-K2530.
[0191] It has been confirmed that the toner transparency depends on
the dispersion unit, the dispersed particle diameter and the
dispersion morphology of wax in the toner. Belt fixing units are
inferior to roller fixing units in terms of toner fixing, since the
surface pressure for toner fixing in the former is lower tan that
in the latter. In the former, therefore, the action of the
releasing agent in the toner is more important than in the latter.
To solve the problem of toner transparency, the dispersion unit of
wax particles in the toner is so controlled that the particle
diameter and the morphology of the wax particles in each toner
particle have no influence on the toner transparency, and, in
addition, the dispersion condition of wax particles in the binder
resin is also suitably controlled so as to solve the problem of
toner transparency irrespective of the degree of crystallinity of
wax. The wax parameters have significant influences not only on the
toner transparency but also on the hot-offset resistance of
toner.
[0192] The dispersibility of wax in the toner of the present
invention prepared according to method mentioned hereinabove
(granulation in aqueous medium) significantly differs from that of
ordinary toner prepared in a premix grinding method or a
polymerization method. Specifically, in a premix grinding method,
fine dispersion of ground toner particles is limited, and it is not
easy to produce fine toner particles having a particle diameter of
2 .mu.m or less. In addition, in the method, the grinding stress is
often concentrated on the interface between wax and resin, and
therefore wax is often released out of the surfaces of the toner
particles. Thus released out, the wax is effective for lubricating
the toner particles and therefore for preventing hot offsetting,
but is disadvantageous to the transparency of color toners. On the
other hand, in toner particles prepared through suspension
polymerization, wax is enveloped in resin through vinyl
polymerization, and it is almost ineffective for improving the
transparency of the toner particles prepared. Also in emulsion
polymerization to prepare toner particles, it is in fact almost
impossible to fine disperse wax in the toner particles produced
through vinyl polymerization. Contrary to these methods, the method
of preparing the toner of the present invention is favorable for
finely dispersing wax particles in toner particles, since the
shape, the morphology and the particle diameter of the wax
particles to be finely dispersed in the toner particles can be
relatively easily controlled. The shape, diameter and the state of
wax particle existing in the toner particle affects fixing quality,
specifically fixing temperature (hot offsetting) in the belt fixing
where fixing in low surface pressure is desired. That is, when the
wax particle exists in the vicinity of the particle surface,
specifically when the wax particle exists along the surface layer
of the toner particle, wax may promptly permeate into the surface
of the toner particle to show satisfying releasing ability while
there is a problem of wax particle tends to expose at the surface
of the toner particle. On the other hand, when the wax particle is
dispersed deep inside the toner particle, hot offset resistance
deteriorates due to permeation of the wax particle into the surface
of the toner particle becomes difficult, hence releasing ability
deteriorates.
[0193] A well balanced state of the wax particle in the toner
particle is to have the wax particle exist in the vicinity of the
surface of the toner particle to orient the maximum diameter of the
wax particle to the direction of the toner particle core in
acicular-like state, so that exposing of wax particles at the
surface of the toner particle is likely be suppressed, and are well
dispersed to easily permeate under heat at the time of fixing. Such
state of dispersion of wax particles in the toner particle is
realized by dispersing 10 to 200% of wax dispersant to the wax so
as to disperse wax against polyester or modified polyester to form
islands of wax and resin (polyester or modified polyester). A
suitable wax dispersant may be styrene and acryl copolymers, such
as copolymer of styrene, nBMA, and BA (MW50000), or copolymer of
styrene and BA (MW80000). When the amount of dispersant is large
with respect to the wax, wax particles are dispersed deep inside
the toner particle while the amount thereof is less, wax particles
are dispersed in the vicinity of the toner surface.
[0194] A method for measuring the dispersed particle diameter of
wax in the toner of the present invention is described
concretely.
[0195] In the present invention, the dispersed particle diameter of
wax is indicated by the major diameter of each wax particle
dispersed in toner particles. Concretely, a sample of the toner is
embedded in an epoxy resin, and it is cut into ultra-tin slices of
about 100 .mu.m thick. Stained with ruthenium tetroxide, the slice
is observed with a transmission electronic microscope (TEM) having
a magnification of 1000 to 10,000, and its picture is taken through
the microscope. The image of the picture is analyzed to know the
wax dispersion condition in toner particles and to measure the
dispersed particle diameter of the wax particles.
[0196] The wax dispersion distribution in the toner of the present
invention is preferably such that wax particles of 0.1 to 2 .mu.m
in particle diameter account for 70% or more by number, more
preferably those of 0.5 .mu.m to 1 .mu.m account for 70% or more by
number. The reason why such wax particles not smaller than 0.1
.mu.m are preferred is because their lubricating ability is good.
If large wax particles having a maximum length of larger than 3
.mu.m account for 5% or more of all wax particles, they will
aggregate and lower the flowability of the toner. If so, in
addition, such large wax particles cause a problem of toner
findings and greatly lower the color reproducibility and the
glossiness of color toners. For these reasons, such large wax
particles are unfavorable in the present invention.
[0197] Also preferably, the wax particles are relatively uniformly
dispersed inside the toner particles, and 3 wax particles or more
are in one toner particle. In addition, in view of the fixing
ability and the releasing ability of the toner, it is also
desirable that the toner particles each carrying less than 3 wax
particles therein do not exceed 30% by number of all the toner
particles seen in the TEM picture.
[0198] Referring to the wax dispersion condition in the toner
particles seen in the TEM picture, the wax particles are preferably
so oriented in each toner particle that the major diameter of each
wax particle is not parallel to the surface of the toner particle,
or that is, the wax particles are dispersed toward the inside of
the toner particle. This is because the toner particles with wax
particles dispersed inside them are well flowable and their charge
fluctuation is relatively small, but those in which the wax
particles extend along the particle surface and are exposed has a
problem in the charge stability and the flowability as seen in
ground toner particles, while satisfies releasing ability.
[0199] Colorant
[0200] For the colorant for the toner of the present invention,
employable are all known dyes and pigments. For example, herein
employable are carbon black, nigrosine dye, iron black, Naphthol
Yellow S, Hansa Yellow (10G, 5G, G), cadmium yellow, yellow iron
oxide, ochre, chrome yellow, titanium yellow, polyazo yellow, oil
yellow, Hansa Yellow (GR, A, RN, R), Pigment Yellow L, Benzidine
Yellow (G, GR), Permanent Yellow (NCG), Vulcan Fast Yellow (5G, R),
tartrazine lake, quinoline yellow lake, Anthrazan Yellow BGL,
isoindolinone yellow, red iron oxide, red lead, lead vermilion,
cadmium red, cadmium mercury red, antimony red, Permanent Red 4R,
para red, fire Red, parachloro-orthonitroaniline red, Lithol Fast
Scarlet G, brilliant fast scarlet, Brilliant Carmine BS, Permanent
Red (F2R, F4R, FRL, FRLL, F4RH, Fast Scarlet VD, Vulcan fast rubin
B, Brilliant Scarlet G. Lithol Rubin GX, Permanent Red F5R,
Brilliant Carmine 6B, Pigment Scarlet 3B, Bordeaux 5B, toluidine
maroon, Permanent Bordeaux F2K, Helio Bordeaux BL, Bordeaux 10B,
BON maroon light, BON maroon medium, eosine lake, Rhodamine Lake B,
Rhodamine Lake Y, alizarine lake, Thioindigo Red B, thioindigo
maroon, oil red, quinacridone red, pyrazolone red, polyazo red,
chrome vermilion, benzidine orange, perinone orange, oil orange,
cobalt blue, cerulean blue, alkali blue lake, peacock blue lake,
Victoria blue lake, metal-free phthalocyanine blue, phthalocyanine
blue, fast sky blue, Indanthrene Blue (RS, BC), indigo, ultramrine,
prussian blue, anthraquinone blue, Fast Violet B. methyl violet
lake, cobalt violet, manganese violet, dioxane violet,
anthraquinone violet, chrome green, zinc green, chromium oxide,
viridian, emerald green, Pigment Green B, Naphthol Green B, green
gold, acid green lake, malachite green lake, phitalocyanine green,
anthraquinone green, titanium oxide, zinc flower, lithopone, and
their mixtures. The amount of the colorant to be in the toner may
be generally 1 to 15% by weight, preferably 3 to 10% by weight of
the toner
[0201] The colorant used in the present invention may be used as
master batch compounded with resin. The binder resin to be used in
preparing the master batch or to be mixed with the master batch may
be any of the abovementioned, modified or non-modified polyester
resins, as well as styrene polymers and substituted styrene
polymers such as polystyrene, poly-p-chlorostyrene,
polyvinyltoluene; styrene copolymers such as
styrene-p-chlorostyrene copolymer, styrene-propylene copolymer,
styrene-vinyltoluene copolymer, styrene-vinylnaphthalene copolymer,
styrene-methyl acrylate copolymer, styrene-ethyl acrylate
copolymer, styrene-butyl acrylate copolymer, styrene-octyl acrylate
copolymer, styrene-methyl methacrylate copolymer, styrene-ethyl
methacrylate copolymer, styrene-butyl methacrylate copolymer,
styrene-methyl .alpha.-chloromethacrylate copolymer,
styrene-acrylonitrile copolymer, styrene-vinyl methyl ketone
copolymer, styrene-butadiene copolymer, styrene-isoprene copolymer,
styrene-acrylonitrile-indene copolymer, styrene-maleic acid
copolymer, styrene-maleate copolymers; and polymethyl methacrylate,
polybutyl methacrylate, polyvinyl chloride, polyvinyl acetate,
polyethylene, polypropylene, polyesters, epoxy resins, epoxy-polyol
resins, polyurethanes, polyamides, polyvinylbutyral, polyacrylic
acid resins, rosin, modified rosins, terpene resins, aliphatic or
alicyclic hydrocarbon resins, aromatic petroleum resins,
chloroparaffins, paraffin wax. These may be used alone or in
combination.
[0202] The master batch may be prepared by mixing and kneading the
resin for master batch and the colorant with high shear force being
applied thereto. In this case, an organic solvent may be added to
the mixture for improving the interaction between the colorant and
the resin. A flashing method is favorable to preparing the master
batch, which comprises premixing an aqueous paste of colorant with
resin along with an organic solvent to thereby transfer the
colorant to the resin phase, followed by removing water and the
organic solvent from the resulting premix. In is method, wet cake
of colorant can be directly used, not dried. For premixing the
components, preferred is a high-shear dispersing device such as a
three-roll mill,
[0203] Charge-Controlling Agent:
[0204] If desired, the toner of the present invention may contain a
charge-controlling agent. For the charge-controlling agent, herein
usable are all known ones. For example, it includes nigrosine dyes,
triphenylmethane dyes, chromium-containing metal complex dyes,
molybdate chelate pigments, rhodamine dyes, alkoxyamines,
quaternary ammonium salts (including fluoro-modified quaternary
ammonium salts), alkylamides, phosphor and its compounds, tungsten
and its compounds, fluorine-containing surfactants, metal
salicylates, and metal salicylate derivatives. Concretely, they are
Bontron 03, a type of nigrosine dye; Bontron P-51, a type of
quaternary ammonium salt; Bontron S-34, a type of metal-containing
azo dye; E-82, a type of hydroxynaphthoic acid-metal complex; E-84,
a type of salicylic acid-metal complex; E-89, a type of phenolic
condensate (these are all by Orient Chemical Industry); quaternary
ammonium salt-molybdenum complexes, TP-302 and TP-415 (these are by
Hodogaya Chemical Industry); Copy Charge PSY VP2038, a type of
quaternary ammonium salt; Copy Blue PR, a type of triphenylmethane
derivative; quaternary ammonium salts, Copy Charge NEG VP2036 and
Copy Charge NX VP434 (these are all by Hoechst); LRA-901; LR-147, a
type of boron complex (these are by Nippon Carlit); as well as
copper phthalocyanine, perylene, quinacridone and azo pigments, and
other polymer compounds having a functional group of, for example,
sulfonic acid groups, carboxyl groups or quaternary ammonium
salts.
[0205] In the present invention, the amount of the
charge-controlling agent to be in the toner is determined,
depending on the type of the binder resin and the presence or
absence of any optional additives in the toner, and on the method
of preparing the toner including dispersing the constitutive
components, and therefore could not be determined unconditionally.
Preferably, however, the amount is 0.1 to 10 parts by weight, more
preferably 0.2 to 5 parts by weight, relative to 100 parts by
weight of the binder resin in the toner. If it is larger than 10
parts by weight, the toner will be too much charged, and will
therefore detract from the effect of the principal
charge-controlling agent essentially used in the method for fixing
toner. If so, the static attraction force of the toner to the
development roller will increase, the flowability of the developer
used will decrease, and the image density will decrease. The
charge-controlling agent and the releasing agent may be premixed
with the master batch or the binder resin. Needless-to-say, these
may be added to the toner components while they are dissolved or
dispersed in an organic solvent.
[0206] Additive:
[0207] One preferred additive to the toner of the present invention
for assisting the flowability, the developability and the charge
property of the toner is inorganic particles. Preferably, the
primary particle diameter of the inorganic particles is 5 m.mu. to
2 .mu.m, more preferably 5 m.mu. to 500 m.mu.. Also preferably, the
specific surface area of the inorganic particles, measured
according to the BET method, is 20 to 500 m.sup.2/g. The amount of
the inorganic particles to be used is preferably 0.01 to 5% by
weight of the toner, more preferably 0.01 to 2% by weight Examples
of the inorganic particles are silica, alumina, titanium oxide,
barium titanate, magnesium titanate, calcium titanate, strontium
titanate, zinc oxide, tin oxide, silica sand, clay, mica,
wollastonite, diatomaceous earth, chromium oxide, cerium oxide, red
iron oxide, antimony trioxide, magnesium oxide, zirconium oxide,
barium sulfate, barium carbonate, calcium carbonate, silicon
carbide, and silicon nitride. Especially preferably, hydrophobic
silica particles are combined with hydrophobic titanium oxide
particles for the flowability improver.
[0208] Especially when these two types of particles having a mean
particle diameter of 50 m.mu. or less are combined to prepare a
flowability improver and mixed with the toner by stirring them, the
electrostatic force and the Van der Waals force of the flowability
improver to the toner are significantly high. Therefore, even when
the toner components are mixed along with the flowability improver
by stirring them inside developing machines for obtaining the
desired charge level, the flowability improver does not remove from
the toner particles. As a result, the toner gives good images with
no white spot, and, in addition, the untransferred toner residue is
reduced. We, the inventors have clarified the advantages of the
flowability improver.
[0209] Titanium oxide particles are favorable to the environment
and are effective for stabilizing image density, but on the other
hand, they are problematic in that the charge rise time is often
long when they are used. Therefore, if the amount of titanium oxide
particles is larger than that of silica particles when these two
type of particles are combined to be a flowability improver, the
negative influence of the side effect of titanium oxide particles
on the toner fixing ability will be remarkable. However, when the
amount of hydrophobic silica particles and hydrophobic titanium
oxide particles is within the range of 0.3 to 1.5% by weight, it
does not significantly detract from the charge rise of the toner
and the toner could have the desired charge rise characteristic.
Accordingly, even when copying with the toner is repeated many
times, it still gives good images of stable and high quality, and
toner scattering is prevented. We, the inventors have also found
the advantages of the flowability improver.
[0210] Method for Preparing Modified Polyester Resin:
[0211] The toner binder resin may be prepared according to the
method mentioned below. A polyol (1) and a polycarboxylic acid (2)
are heated at 150 to 280.degree. C. in the presence of a known
esterification catalyst such as tetrabutoxy titanate or dibutyltin
oxide to obtain a hydroxyl group-having polyester while water given
by the reaction is evaporated away optionally under reduced
pressure. Next, the polyester is reacted with a polyisocyanate (3)
at 40 to 140.degree. C. to obtain an isocyanate group-having
prepolymer (A). Further the prepolymer (A) is reacted with an amine
(B) at 0 to 140.degree. C. to obtain a polyester modified with urea
bonds (i).
[0212] When the polyester is reacted with (3) and when (A) is
reacted with (B), optionally used is a solvent The solvent is inert
to the isocyanate (3), including, for example, aromatic solvents
(e.g., toluene, xylene); ketones (eg., acetone, methyl ethyl
ketone, methyl isobutyl ketone); esters (e.g., ethyl acetate);
amides (e.g., dimethylformamide, dimethylacetamide); and ethers
(e.g., tetrahydrofuran). In case where the modified polyester (i)
is combined with a polyester (ii) not modified with urea bonds for
the binder resin, (ii) is prepared in the same manner as above for
producing the hydroxyl group-having polyester, and his is dissolved
in the solution of (i) and mixed with it after the reaction to give
(i) has been completed.
[0213] The dry toner of the present invention may be prepared
according to the method mentioned below, to which, the present
invention is not limited.
[0214] Method for Preparing Toner in Aqueous Medium
[0215] The aqueous medium to be used in preparing the toner of the
present invention may be water alone or may be a mixture of water
with a water-miscible solvent The water-miscible solvent includes,
for example, alcohols (e.g., methanol, isopropanol, ethylene
glycol), dimethylformamide, tetrahydrofuran, cellosolves (e.g.,
methyl cellosolve), and lower ketones (e.g., acetone, methyl ethyl
ketone).
[0216] To form the toner particles, a dispersion of the isocyanate
group-having prepolymer (A) may be reacted with (B) in such an
aqueous medium to give a binder resin, or alternatively, the
urea-modified polyester (i) having been previously prepared may be
used as the binder resin. For stabilizing the urea-modified
polyester (i) or the dispersion of prepolymer (A) in an aqueous
medium to form the toner particles, for example, a toner
composition comprising the urea-modified polyester (i) or the
prepolymer (A) is added to an aqueous medium and dispersed therein
by shear force. The prepolymer (A) may be mixed with the other
toner components (hereinafter referred to as toner materials),
colorant, colorant master batch, releasing agent,
charge-controlling agent, non-modified polyester resin and others,
while its dispersion is formed in an aqueous medium. Preferably,
however, the toner materials are previously mixed, and the
resulting mixture is added to an aqueous medium that contains a
dispersion of the prepolymer (A). In the present invention, it is
not always necessary that the other toner materials such as
colorant, releasing agent and charge-controlling agent are in the
aqueous medium in which the toner particles are formed, but they
may be added to the aqueous medium after the toner particles have
been formed therein. For example, toner particles not containing a
colorant are formed, and a colorant may be added thereto according
to a known toner-coloring method.
[0217] The method of dispersing the toner materials is not
specifically defined, for which, for example, usable are any known
dispersers such as low-speed shearing dispersers, high-speed
shearing dispersers, frictional dispersers, high-pressure jet
dispersers, or ultrasonic dispersers. Of those, preferred are
high-speed shearing dispersers for forming toner particles having a
particle diameter of 2 to 20 .mu.m. The number of revolutions of
the high-speed shearing disperser is not specifically defined, for
example, generally ranging from 1000 to 30,000 rpm, preferably 5000
to 20,000 rpm. The time for dispersing the toner materials is not
also specifically defined, for example, generally ranging from 0.1
to 5 minutes for batch dispersion. The temperature at which the
toner materials are dispersed may be generally 0 to 150.degree. C.
(under pressure), preferably 40 to 98.degree. C. Higher
temperatures are more preferred, at which the viscosity of the
dispersion of the urea-modified polyester (i) or the prepolymer (A)
is low and the component is easier to disperse.
[0218] The amount of the aqueous medium to be used herein may be
generally 50 to 2,000 parts by weight, preferably 100 to 1000 parts
by weight relative to 100 parts by weight of the toner composition
that contains the urea-modified polyester (i) or the prepolymer
(A). If it is smaller than 50 parts by weight, the toner
composition could not well disperse in the aqueous dispersion, and
the particle diameter of the toner particles formed could not reach
a predetermined level. If, however, the amount of the aqueous
medium is larger tan 2,000, it is uneconomical. If desired, a
dispersant may be added to the aqueous medium. Adding a dispersant
thereto is preferred since the toner particles formed may have a
sharper particle diameter distribution and their dispersion is more
stable.
[0219] For the dispersant that promotes the emulsification and
dispersion of the oily-phase toner dispersion in the aqueous
medium, for example, usable are anionic surfactants such as salts
of alkylbenzenesulfonic acids, salts of .alpha.-olefinsulfonic
acids, phosphates; amine-type cationic surfactants such as
alkylamine salts, aminoalcohol-fatty acid derivatives,
polyamine-fatty acid derivatives, imidazoline; quaternary ammonium
salt-type cationic surfactants such as alkyltrimethylammonium
salts, dialkyldimethylammonium salts, alkyldimethylbenzylammonium
salts, pyridinium salts, alkylisoquinolinium salts, benzetonium
chloride; nonionic surfactants such as fatty acid amide
derivatives, polyhydric alcohol derivatives; and ampholytic
surfactants such as alanine, dodecyldi(aminoethyl)glycine,
di(octylaminoethyl)glycine, N-alkyl-N,N-dimethylammonium
betaines.
[0220] Fluoroalkyl group-having surfactants are effective for the
dispersant, even through their amount used is extremely small.
Preferred examples of fluoroalkyl group-having anionic surfactants
for use herein are fluoroalkyl(C.sub.2-10)carboxylic acids and
their salts, disodium perfluorooctanesulfonylglutaminate, sodium
3-[omega-fluoroalkyl(C.sub.6-1- 1)oxy]1-alkyl(C.sub.3-4)sulfonates,
sodium 3-[omega-fluoroalkanoyl(C.sub.6-
-8)-N-ethylamino]-1-propanesulfonates,
fluoroalkyl(C.sub.11-20)carboxylic acids and their metal salts,
perfluoroalkyl(C.sub.7-13)carboxylic acids and their salts,
perfluoroalkyl(C.sub.4-12)sulfonic adds and their salts,
perfluorooctanesulfonic acid diethanolamide,
N-propyl-N-(2-hydroxyethyl)p- erfluorooctanesulfonamide,
perfluoroalkyl(C.sub.6-10)sulfonamidopropyltrim- ethylammonium
salts, perfluoroalkyl(C.sub.6-10)-N-ethylsulfonylglycine salts,
monoperfluoroalkyl(C.sub.6-16)ethyl phosphates.
[0221] Their commercial products are, for example, Sarfron S-111,
S-112, S-113 (by Asahi Glass); Frorard FC-93, FC-95, FC-98, FC-129
(by Sumitomo 3M); Unidyne DS-101, DS-102 (by Daikin Industries);
Megafac F-110, F-120, F-113, F-191, F812, F833 (by Dai-Nippon Ink
& Chemicals); Extop EF-102, 103, 104, 105, 112, 123A, 123B,
306A, 501, 201, 204 (by Tochem Products); and Ftergent F-100, F-150
(by Neos).
[0222] Examples of cationic surfactants usable herein are
fluoroalkyl group-having primary, secondary or tertiary amines,
aliphatic quaternary ammonium salts such as
perfluoroalkyl(C.sub.6-10)sulfonamidopropyltrimeth- ylammonium
salts, and benzalkonium salts, benzetonium chloride, pyridinium
salts, imidazolinium salts. Their commercial products are, for
example, Sarfron S-121 (by Asahi Glass); Frorard FC-135 (by
Sumitomo 3M); Unidyne DS-202 (by Daikin Industries); Megafac F150,
F-824 (by Dai-Nippon Ink & Chemicals); Extop EF-132 (by Tochem
Products), and Ftergent F-300 (by Neos).
[0223] Inorganic compounds hardly soluble in water are also usable
for the dispersant herein, including, for example, tricalcium
phosphate, calcium carbonate, titanium oxide, colloidal silica and
hydroxyapatite.
[0224] If desired, the dispersion drops may be stabilized with a
protective polymer colloid. The stabilizer includes, for example,
homopolymers and copolymers of acids (e.g., acrylic acid,
methacrylic acid, .alpha.-cyanoacrylic acid,
.alpha.-cyanomethacrylic acid, itaconic acid, crotonic add, fumaric
acid, maleic acid, maleic anhydride), or OH-having (meth)acrylic
monomers (e.g., .beta.-hydroxyethyl acrylate, .beta.-hydroxyethyl
methacrylate, .beta.-hydroxypropyl acrylate, .beta.-hydroxypropyl
methacrylate, .gamma.-hydroxypropyl acrylate, .gamma.-hydroxypropyl
methacrylate, 3-chloro-2-hydroxypropyl acrylate,
3-chloro-2-hydroxypropyl methacrylate, diethylene glycol
monoacrylate, diethylene glycol monomethacrylate, glycerin
monoacrylate, glycerin monomethacrylate, N-methylolacrylamide,
N-methylolmethacrylamide), or vinyl alcohols or vinyl alcohol
ethers (e.g., vinyl methyl ether, vinyl ethyl ether, vinyl propyl
ether), or esters of carboxyl having compounds with vinyl alcohols
(e.g, vinyl acetate, vinyl propionate, vinyl butyrate), or
acrylamide, methacrylamide, diacetonacrylamide or their methylol
compounds, or acid chlorides (e.g., acrylic chloride, methacrylic
chloride), or nitrogen atom-having or heterocyclic monomers (e.g.,
vinylpyridine, vinylpyrrolidone, vinylimidazole, ethyleneimine);
polyoxyethylene-type polymers such as polyoxyethylene,
polyoxypropylene, polyoxyethylene alkylamines, polyoxypropylene
alkylamines, polyoxyethylene alkylamides, polyoxypropylene
alkylamides, polyoxyethylene nonylphenyl ether,
polyoxyethylenelaurylphenyl ether, polyoxyethylene stearylphenyl
ester, polyoxyethylene nonylphenyl ester; and celluloses such as
methyl cellulose, hydroxyethyl cellulose, hydroxypropyl
cellulose.
[0225] From the emulsified dispersion, the organic solvent is
removed. For this, for example, the system is gradually heated, and
the organic solvent in the liquid drops therein is completely
evaporated away. Alternatively, the emulsified dispersion may be
sprayed into a dry atmosphere to completely remove the
water-insoluble organic solvent from the liquid drops therein to
form toner particles while, at the same time, the aqueous
dispersant is also evaporated away from the toner particles. For
the dry atmosphere into which the emulsified dispersion is sprayed,
generally employed are various types of hot vapors of, for example,
air, nitrogen, carbon dioxide or combustion gas, especially those
heated at a temperature of the boiling point or more of the
highest-boiling-point solvent used. Thus processed in a spray
drier, a belt drier or a rotary kiln for a short period of time,
the emulsified dispersion gives high-quality toner particles well
satisfying the object of the present invention.
[0226] In case where a dispersion stabilizer soluble in acid or
alkali, such as calcium phosphate is used, it may be dissolved in
an acid such as hydrochloric acid and then the toner particles may
be washed with water to thereby remove the dispersion stabilizer,
calcium phosphate from the toner particles. Alternatively, it may
also be removed from the toner particles through enzymolysis.
[0227] The dispersant may remain on the surfaces of the toner
particles. However, in view of the charge property of the toner,
the dispersant is preferably washed away after chain extension
and/or crosslinking reaction of the binder resin in the toner
particles.
[0228] For further lowering the viscosity of the toner composition,
also usable is a solvent capable of dissolving the urea-modified
polyester (i) and the polyester prepolymer (A). Using the solvent
is preferred as it sharpens the particle diameter distribution of
the toner particles formed. Preferably, the solvent is volatile,
having a boiling point of lower than 100.degree. C., as it is easy
to remove. Examples of the solvent are toluene, xylene, benzene,
carbon tetrachloride, chloromethylene, 1,2-dichloroethane,
1,1,2-trichloroethane, trichloroethylene, chloroform,
monochlorobenzene, dichloroethylidene, methyl acetate, ethyl
acetate, methyl ethyl ketone, and methyl isobutyl ketone. One or
more of these may be used alone or in combination Especially
preferred are aromatic solvents such as toluene, xylene, and
halogenohydrocarbons such as chloromethylene, 1,2-dichloroethane,
chloroform, and c=bon tetrachloride. The amount of the solvent to
be used may be generally 0 to 300 parts, preferably 0 to 100 parts,
more preferably 25 to 70 parts relative to 100 parts of the
prepolymer (A). The solvent, if used, is removed by heating the
system under atmospheric pressure or reduced pressure after chain
extension and/or crosslinking reaction of the binder resin.
[0229] The time for chain extension and/or crosslinking reaction of
the binder resin is determined in accordance with the reactivity of
the isocyanate structure which the prepolymer (A) possesses with
the amine (B) to be reacted with it, and it therefore varies,
depending on the combination of the two. In general, the time is 10
minutes to 40 hours, preferably 2 to 24 hours. The reaction
temperature is generally 0 to 150.degree. C., preferably 40 to
98.degree. C. If desired, any known catalyst may be used in the
reaction. Concretely, for example, dibutyltin laurate or dioctyltin
laurate may be used.
[0230] From the emulsified dispersion, the organic solvent is
removed. For this, for example, the system is gradually heated, and
the organic solvent in the liquid drops therein is completely
evaporated away. Alternatively, the emulsified dispersion may be
sprayed into a dry atmosphere to completely remove the
water-insoluble organic solvent from the liquid drops therein to
form toner particles while, at the same time, the aqueous
dispersant is also evaporated away from the toner particles. For
the dry atmosphere into which the emulsified dispersion is sprayed,
generally employed are various types of hot vapors of, for example,
air, nitrogen, carbon dioxide or combustion gas, especially those
heated at a temperature of the boiling point or more of the
highest-boiling-point solvent used. Thus processed in a spray
drier, a belt drier or a rotary kiln for a short period of time,
the emulsified dispersion gives high-quality toner particles well
satisfying the object of the present invention.
[0231] In case where the particle diameter distribution of the
emulsified dispersion is broad, and the dispersion is washed and
dried while it has such a broad particle diameter distribution, the
resulting particles may be classified and dressed to select those
having a desired particle diameter distribution.
[0232] For example, the particles still in liquid are processed in
a cyclone, a decanter or a centrifuge to remove fine powdery
particles from them. Needless-to-say, the particles may be
classified after dried. In view of the efficiency of the classifier
used, it is desirable that the particles still in liquid are
directly classified as they are. Thus separated, the unnecessary
fine powdery particles or coarse particles are recirculated into
the premixing step and are used for forming toner particles. In his
case, the powdery particles and the coarse particles may be
wet.
[0233] Thus obtained, the dry toner particles are mixed with
additive particles such as releasing agent particles,
charge-controlling agent particles, flowability improver particles
and colorant particles and the resulting mixture is optionally
exposed to mechanical impact applied thereto, whereby the additive
particles are well fixed and fused to the surfaces of the toner
particles so as not to drop off from the surfaces of the resulting
composite particles of toner.
[0234] Concretely, for example, the mixture is put in a stirrer, in
which the stirring blades are rotated at high speed to impart
impact force to the mixture therein; or the mixture is led into jet
streams and accelerated so as to make the toner particles or the
composite toner particles collide with each other or against
collision baffles. For the purpose, various devices may be used,
for example, Angmill (by Hosokawa Micron) and I-type Mill (by
Nippon Pneumatic) that are modified to lower the attrition air
pressure therein, as well as Hybridization System (by Nara
Machinery Manufacturing), Cryptoron (by Kawasaki Heavy Industries),
and automatic mortars.
[0235] Carrier for Two-Component Developer
[0236] In case where the toner of the invention is used for a
two-component developer, it may be mixed with a magnetic carrier.
Regarding the blend ratio of toner to carrier in the developer, it
is desirable that the amount of the toner is 1 to 10 parts by
weight relative to 100 parts by weight of the carrier. The magnetic
carrier may be any known one, including, for example, iron powder,
ferrite powder, magnetite powder or magnetic resin carrier having a
particle diameter of 20 to 200 .mu.m or so. The carrier particles
may be coated with any of amino resin, e.g., urea-formaldehyde
resin, melamine resin, benzoguanamine resin, urea resin or
polyamide resin, or epoxy resin. For the coating material, also
usable are polyvinyl or polyvinylidene resin such as acrylic resin,
polymethyl methacrylate resin, polyacrylonitrile resin; polyvinyl
acetate resin polyvinyl alcohol resin, polyvinyl butyral resin;
polystyrene resin and other polystyrenic resin such as
styrene-acrylic copolymer resin; halo-olefinic resin such as
polyvinyl chloride; polyester resin such as polybutylene
terephthalate resin; polycarbonate resin, polyethylene resin,
polyvinyl fluoride resin, polyvinylidene fluoride resin,
polytfluoroethylene resin, polyhexafluoropropylene resin, copolymer
of vinylidene fluoride and acrylic monomer, copolymer of vinylidene
fluoride and vinyl fluoride; fluoro-terpolymer such as terpolymer
of tetrafluoroethylene, vinylidene fluoride and non-fluoro monomer;
and silicone resin. If desired, electroconductive powder may be in
the coating resin. The electroconductive powder includes, for
example, metal powder, carbon black, titanium oxide, tin oxide,
zinc oxide. Preferably, the electroconductive powder has a mean
particle diameter of 1 .mu.m or less. If its mean particle diameter
is larger than 1 .mu.m, the electric resistance of the resin-coated
carrier particles will be difficult to control. Not combined with
such a carrier, the toner of the present invention may also be a
one-pack magnetic or non-magnetic toner.
[0237] Method of Measuring the Roundness of Toner:
[0238] It is a matter of importance that the toner particles of the
present invention have a mean roundness of 0.96 to 1.00 and have a
specific morphology and a specific morphology distribution. If
their mean roundness is smaller than 0.96, the toner particles are
far from spheres and will be amorphous. Toner of which the
particles having a roundness of smaller than 0.95 account for 30%
or more of all the particles could not meet the recent requirement
in the art of giving high-quality images. Amorphous toner particles
have many contact points with flat media such as photoconductor,
and their hilltops will receive much charge concentrated thereto.
As a result, the attracting force such as Van der Waals force or
image force of amorphous toner particles is higher than that of
spherical toner particles. Accordingly, when a toner containing
both amorphous particles and spherical particles is used in an
electrostatic image-transferring step, the spherical toner
particles selectively migrate to cause non-image spots in the
letter or line images formed. One method of measuring the roundness
of toner particles is described hereinunder.
[0239] For analyzing the morphology of toner particles, for
example, suitable is a method of optical inspection that comprises
letting a particle suspension into an image pickup zone on a flat
plate, taking an optical image of the particles with a CCD camera,
and analyzing the image. The circumferential length of a circle of
which the area is the same as the projected area of the particle
image analyzed herein is divided by the circumferential length of
the projected area of the particle itself, and it gives the
roundness of the particle. We, the present inventors have found
that a toner having a mean roundness of 0.96 or more and contains
30% or less of particles having a mean roundness of smaller than
0.95 is effective for forming reproducible high-precision images of
good density. More preferably, the toner has a mean roundness of
0.98 to 1.00 and contains 10% or less of particles having a mean
roundness of smaller than 0.95. The mean particle roundness of
toner can be measured with a flow particle image analyzer,
FPIA-2100 (by Toa Medical Electronics). Concretely, 0.1 to 0.5 ml
of a surfactant that serves as a dispersant, preferably a salt of
an alkylbenzenesulfonic acid is added to 100 to 150 ml of water
from which solid impurities have been previous removed, in a
container, and then about 0.1 to 0.5 g of a toner sample to be
analyzed is added thereto. The resulting suspension thus containing
the sample dispersed therein is then further dispersed in an
ultrasonic disperser for about 1 to 3 minutes to prepare a toner
dispersion having a concentration of 3000 to 10,000
particles/.mu.l, and this is analyzed using the above-mentioned
image analyzer to determine the particle morphology and the
particle dispersion distribution of the toner sample.
EXAMPLES
[0240] The present invention is described in more detail with
reference to the following Examples, which, however, are not
intended to restrict the scope of the present invention. In the
following, "parts" are all by weight.
[0241] The physical properties of the toners prepared and used in
the Examples are shown in Table 1 below.
Example 1
[0242] Preparation of Toner Binder
[0243] 780 parts of bisphenol A-ethylene oxide (2 mols) adduct, 280
parts of isophthalic acid and 2 parts of dibutyltin oxide were put
into a reactor equipped with a condenser tube, a stirrer and a
nitrogen-introducing duct, and reacted therein for 6 hours at
230.degree. C. under atmospheric pressure, and then for 3 hours
under a reduced pressure of 10 to 15 mmHg. After this was cooled to
160.degree. C., 32 parts of phthalic anhydride was added thereto
and reacted for 2 hours. Next, this was cooled to 80.degree. C.,
and reacted with 198 parts of isophorone diisocyanate in ethyl
acetate for 2 hours to give an isocyanate-having prepolymer (1).
Next, 267 parts of the prepolymer (1) was reacted with 12 parts of
isophoronediamine at 50.degree. C. for 2 hours to give an
urea-modified polyester (1) having a weight-average molecular
weight of 54,000. In the same manner as above, 724 parts of
bisphenol A-ethylene oxide (2 mols) adduct and 276 parts of
terephthalic acid were polycondensed at 230.degree. C. under
atmospheric pressure for 8 hours and then further reacted for 5
hours under a reduced pressure of 10 to 15 mmHg to give a
non-modified polyester (a) having a peak molecular weight of 5000.
100 parts of the urea-modified polyester (1) and 900 parts of the
non-modified polyester (a) were mixed by dissolving them in 1800
parts of a solvent ethyl acetate to give a solution of toner binder
(1) in ethyl acetate. This was partly dried under reduced pressure
to isolate the toner binder (1).
[0244] Production of Toner
[0245] 210 parts of the ethyl acetate solution of toner binder (1),
20 parts of pentaerythritol tetrabehenate (melting point 81.degree.
C., needle penetration 2.4, molecular weight 4200, acid value 4.0),
and 4 parts of copper phthalocyanine blue pigment were put into a
beaker, and these were uniformly dissolved and dispersed by
stirring them at 60.degree. C. with a TK-type homomixer at 12,000
rpm. On the other hand, 706 parts of ion-exchanged water, 260 parts
of 10% hydroxyapatite suspension (Nippon Chemical Industry's
Supertite 10), and 0.2 parts of sodium dodecylbenzenesulfonate were
put into a beaker and uniformly dissolved. Next, this was heated up
to 60.degree. C., and with stirring it with a TK-type homomixer at
12,000 rpm, the toner material solution prepared in the above was
added thereto, and stirred for 10 minutes. The resulting mixture
was transferred into a flask equipped with a stirring rod and a
thermometer, and gently stirred for 3 hours with heating up to
98.degree. C. to remove the solvent. This was filtered, washed and
dried, and then pneumatically classified to obtain toner particles
having a weight-average particle diameter of 6 .mu.m. Next, 100
parts of the toner particles were mixed with 0.5 parts of
hydrophobic silica and 0.5 parts of hydrophobic titanium oxide
using a Henschel mixer to obtain a toner (1) of the present
invention. Its GPC chromatograph is FIG. 4, and its test data are
given in Table 2 below. At least 3 wax particles were in each toner
particle, in which wax particles having a dispersed particle
diameter of 0.1 to 2 .mu.m accounted for 90% of all the wax
particles therein. No wax particles of 3 .mu.m or larger were found
in the toner particles. The orientation of the wax particles
dispersed in the toner particles was as in FIG. 5.
Example 2
[0246] Preparation of Toner Binder
[0247] In the same manner as in Example 1, 314 parts of bisphenol
A-ethylene oxide (2 mols) adduct, 314 parts of bisphenol
A-propylene oxide (2 mols) adduct and 20 parts of trimellitic
anhydride were polycondensed, and then reacted with 154 parts of
isophorone diisocyanate to give a prepolymer (2). Next, 213 parts
of the prepolymer (2) was reacted with 9.5 parts of
isophoronediamine and 0.5 parts of dibutylamine also in the same
manner as in Example 1 to give an urea-modified polyester (2)
having a weight-average molecular weight of 79,000. 200 parts of
the urea-modified polyester (2) and 800 parts of the non-modified
polyester (a) were mixed by dissolving them in 2000 parts of a
mixed solvent of ethyl acetate/MEK (1/1) to give a solution of
toner binder (2) in ethyl acetate/MEK This was partly dried under
reduced pressure to isolate the toner binder (2). Its Tg was
65.degree. C., and its acid value was 10.
[0248] Production of Toner
[0249] A toner (2) of the present invention was formulated in the
same manner as in Example 1 except that the dissolving and
dispersing temperature was changed to 50.degree. C. herein. Its
test data are given in Table 2.
[0250] At least 3 wax particles were in each toner particle, in
which wax particles having a dispersed particle diameter of 0.1 to
2 .mu.m accounted for 90% of all the wax particles therein. No wax
particles of 3 .mu.m or larger were found in the toner particles.
The orientation of the wax particles dispersed in the toner
particles was as in FIG. 5.
Example 3
[0251] Preparation of Toner Binder
[0252] 30 parts of the urea-modified polyester (1) and 970 parts of
the non-modified polyester (a) were mixed by dissolving them in
2000 parts of a solvent ethyl acetate to give a solution of toner
binder (3) in ethyl acetate. This was partly dried under reduced
pressure to isolate the toner binder (3).
[0253] Production of Toner
[0254] A toner (3) having a weight-average particle diameter of 6
.mu.m was formulated in the same manner as in Example 1 except that
the toner binder (3) but not the toner binder (1) was used herein.
The number of wax particles having a dispersed particle diameter of
0.1 to 2 .mu.m in each toner particle was counted on 3 TEM pictures
selected at random, resulting in 85% by number on average. No wax
particles of 3 .mu.m or larger were found in the toner particles.
The other test data of the toner (3) are given in Table 2.
Example 4
[0255] Preparation of Toner Binder
[0256] 450 parts of the urea-modified polyester (1) and 450 parts
of the non-modified polyester (a) were mixed by dissolving them in
1900 parts of ethyl acetate to give a solution of toner binder (4)
in ethyl acetate. This was partly dried under reduced pressure to
isolate the toner binder (4).
[0257] Production of Toner
[0258] A toner (4) having a weight-average particle diameter of 6.2
.mu.m was formulated in the same manner as in Example 1 except that
the toner binder (4) but not the toner binder (1) was used herein
The proportion of wax particles having a major diameter of 3 .mu.m
or more in the toner particles was confirmed on the TEM pictures
showing the particle cross sections, and it was 2%. On the TEM
pictures, it was confirmed that all the wax particles were oriented
toward the inside of each toner particle. The test data of the
toner (4) are given in Table 2.
Example 5
[0259] Preparation of Toner Binder
[0260] 815 parts of bisphenol A-ethylene oxide (2 mols) adduct and
215 parts of terephthalic acid were polycondensed for 6 hours at
200.degree. C. under atmospheric pressure, and then further reacted
for 5 hours under a reduced pressure of 30 to 50 mmHg to give a
non-modified polyester (b) having a peak molecular weight of 4000.
100 parts of the urea-modified polyester (1) and 900 parts of the
non-modified polyester (b) were mixed by dissolving them in 2000
parts of ethyl acetate to give a solution of toner binder (5) in
ethyl acetate. This was partly dried under reduced pressure to
isolate the toner binder (5). Its acid value was 0.5.
[0261] Production of Toner
[0262] A toner (5) having a weight-average particle diameter of 8.2
.mu.m was formulated in the same manner as in Example 1 except that
the toner binder (5) but not the toner binder (1) was used herein.
Its test data are given in Table 2.
[0263] At least 3 wax particles were present in each toner
particle, in which wax particles having a dispersed particle
diameter of 0.1 to 2 .mu.m accounted for 90% of all the wax
particles therein. The orientation of the wax particles dispersed
in the toner particles was as in FIG. 5.
Example 6
[0264] Preparation of Toner Binder
[0265] 824 parts of bisphenol A-ethylene oxide (2 mols) adduct and
276 parts of terephthalic acid were polycondensed for 10 hours at
210.degree. C. under atmospheric pressure, and then further reacted
for 5 hours under a reduced pressure of 5 to 20 mmHg to give a
non-modified polyester (c) having a peak molecular weight of 5000.
100 parts of the urea-modified polyester (1) and 900 parts of the
non-modified polyester (c) were mixed by dissolving them in 2000
parts of ethyl acetate to give a solution of toner binder (6) in
ethyl acetate. This was partly dried under reduced pressure to
isolate the toner binder (6).
[0266] Production of Toner
[0267] A toner (6) having a weight-average particle diameter of 5
.mu.m was formulated in the same manner as in Example 1 except that
the toner binder (6) but not the toner binder (1) was used herein.
Its test data are given in Table 2.
[0268] At least 3 wax particles were present in each toner
particle, in which wax particles having a dispersed particle
diameter of 0.1 to 2 .mu.m accounted for 90% of all the wax
particles therein. The orientation of the wax particles dispersed
in the toner particles was as in FIG. 5.
Example 7
[0269] Preparation of Toner Binder
[0270] 724 parts of bisphenol A-ethylene oxide (2 mols) adduct and
276 parts of terephthalic acid were polycondensed for 8 hours at
230.degree. C. under atmospheric pressure, and then further reacted
for 5 hours under a reduced pressure of 10 to 15 mmHg. After this
was cooled to 160.degree. C., 32 parts of trimellitic anhydride was
added thereto and reacted for 2 hours to give a non-modified
polyester (d) having a peak molecular weight of 5000. 100 parts of
the urea-modified polyester (1) and 900 parts of the non-modified
polyester (d) were mixed by dissolving them in 2000 parts of a
mixed solvent of ethyl acetate/MEK (1/1) to give a solution of
toner binder (7) in ethyl acetate/MEW. This was partly dried under
reduced pressure to isolate the toner binder (7). Its acid value
was 25.
[0271] Production of Toner
[0272] A toner (7) having a weight-average particle diameter of 7.2
.mu.m was formulated in the same manner as in Example 1 except that
the toner binder (7) but not the toner binder (1) was used herein.
Its test data are given in Table 2.
Example 8
[0273] Preparation of Toner Binder
[0274] 608 parts of bisphenol A-ethylene oxide (2 mols) adduct and
215 parts of terephthalic acid were polycondensed for 6 hours at
200.degree. C. under atmospheric pressure, and then her reacted for
5 hours under a reduced pressure of 10 to 15 mmHg. After this was
cooled to 160.degree. C., 48 parts of trimellitic anhydride was
added thereto and reacted for 2 hours to give a non-modified
polyester (e) having a peak molecular weight of 15,000. 100 parts
of the urea-modified polyester (1) and 900 parts of the
non-modified polyester (e) were mixed by dissolving them in 2000
parts of ethyl acetate to give a solution of toner binder (8) in
ethyl acetate. This was partly dried under reduced pressure to
isolate the toner binder (8). Its acid value was 35.
[0275] Production of Toner
[0276] A toner (8) having a weight-average particle diameter of 7.2
.mu.m was formulated in the same manner as in Example 1 except that
the toner binder (8) but not the toner binder (1) was used herein.
Its test data are given in Table 2.
Example 9
[0277] Preparation of Toner Binder
[0278] 624 parts of bisphenol A-ethylene oxide (2 mols) adduct and
215 parts of terephthalic acid were polycondensed for 2 hours at
200.degree. C. under atmospheric pressure, and then further reacted
for 5 hours under a reduced pressure of 10 to 15 mmHg to give a
non-modified polyester (f) having a peak molecular weight of 1000.
100 parts of the urea-modified polyester (1) and 900 parts of the
non-modified polyester (f) were mixed by dissolving them in 2000
parts of ethyl acetate to give a solution of toner binder (9) in
ethyl acetate. This was partly dried under reduced pressure to
isolate the toner binder (9).
[0279] Production of Toner
[0280] A toner (9) having a weight-average particle diameter of 8.1
.mu.m was formulated in the same manner as in Example 1 except that
the toner binder (9) but not-the toner binder (1) was used herein.
Its test data are given in Table 2.
Example 10
[0281] Preparation of Toner Binder
[0282] 624 parts of bisphenol A-ethylene oxide (2 mols) adduct and
215 parts of terephthalic acid were polycondensed for 12 hours at
200.degree. C. under atmospheric pressure, and then further reacted
for 5 hours under a reduced pressure of 10 to 15 mmHg to give a
non-modified polyester (i) having a peak molecular weight of
30,000. 100 parts of the urea-modified polyester (1) and 900 parts
of the non-modified polyester (i) were mixed by dissolving them in
2000 parts of ethyl acetate to give a solution of toner binder (10)
in ethyl acetate. This was partly dried under reduced pressure to
isolate the toner binder (10).
[0283] Production of Toner
[0284] A toner (10) having a weight-average particle diameter of
5.2 .mu.m was formulated in the same manner as in Example 1 except
that the toner binder (10) but not the toner binder (1) was used
herein. Its test data are given in Table 2.
Example 11
[0285] Production of Toner:
[0286] A toner (11) having a weight-average particle diameter of
6.8 .mu.m was formulated in the same manner as in Example 1, to
which, however, pentaerythritol tetrabehenate was not added. Its
test data are given in Table 2.
Example 12
[0287] Preparation of Prepolymer
[0288] 800 parts of bisphenol A-ethylene oxide (2 mols) adduct, 200
parts of isophthalic acid, 15 parts of terephthalic acid, and 2
parts of dibutyltin oxide were put into a reactor equipped with a
condenser tube, stirrer and a nitrogen-introducing duct, and
reacted therein at 200.degree. C. under atmospheric pressure for 6
hours, and then for 5 hours under a reduced pressure of 10 to 15
mmHg with removing water. After this was cooled to 160.degree. C.,
30 parts of phthalic anhydride was added thereto and reacted for 2
hours. Next, his was cooled to 80.degree. C., and reacted with 170
parts of isophorone diisocyanate in ethyl acetate for 2 hours to
give an isocyanate-having prepolymer (2) having a weight-average
molecular weight of 12,000.
[0289] Preparation of Ketimine Compound
[0290] 30 parts of isophoronediamine and 70 parts of methyl ethyl
ketone were put into a reactor equipped with a stirring rod and a
thermometer, and reacted therein at 50.degree. C. for 5 hours to
give a ketimine compound (1).
[0291] Production of Toner
[0292] 15.4 parts of the prepolymer (2), 60 parts of the polyester
(a) and 78.6 parts of ethyl acetate were put into a beaker, and
dissolved by stirring them. Next 20 parts of carnauba wax, 5 parts
of styrene acryl dispersant (styrene/nBA), and 4 parts of copper
phthalocyanine blue pigment were added thereto and uniformly
dissolved and dispersed by stirring them at 60.degree. C. with a
TK-type homomixer at 12,000 rpm. Finally, 2.7 parts of the ketimine
compound (1) was added thereto and dissolved. This is a toner
material solution (2). On the other hand, 706 parts of
ion-exchanged water, 260 parts of 10% hydroxyapatite suspension
(Nippon Chemical Industry's Supertite 10), and 0.2 parts of sodium
dodecylbezenesulfonate were put into a beaker and uniformly
dissolved. Next, this was heated up to 60.degree. C., and with
stirring it with a TK-type homomixer at 12,000 rpm, the toner
material solution (2) was added thereto, and stirred for 10
minutes. The resulting mixture was transferred into a flask
equipped with a sting rod and a thermometer, and heated up to
98.degree. C. for urea formation for 2 hours with removing the
solvent. This was filtered, washed and dried, and then
pneumatically classified to obtain toner particles having an uneven
surface morphology and having a weight-average particle diameter of
7 .mu.m. Next, 100 parts of the toner particles were mixed with 0.5
parts of hydrophobic silica and 0.5 parts of hydrophobic titanium
oxide using a Henschel mixer to obtain a toner (12) having a
particle diameter of 7.5 .mu.m of the present invention. Its test
data are given in Table 2.
Example 13
[0293] A toner (13) of the present invention was produced in the
same manner as in Example 12, for which, however, used was an ester
wax (molecular weight 1500, m.p. 85.degree. C., needle penetration
2 mm/50.degree. C., acid value 1.5) in place of the wax used in
Example 12. Its test data are given in Table 2.
Example 14
[0294] Preparation of Prepolymer
[0295] 955 parts of bisphenol A-ethylene oxide (2 mols) adduct, 240
parts of isophthalic acid, 15 parts of terephthalic acid, and 2
parts of dibutyltin oxide were put into a reactor equipped with a
condenser tube, stirrer and a nitrogen-introducing duct, and
reacted therein at 200.degree. C. under atmospheric pressure for 6
hours, and then for 5 hours under a reduced pressure of 50 to 100
mmHg with removing water. After this was cooled to 160.degree. C.,
32 parts of phthalic anhydride was added thereto and reacted for 2
hours. Next, this was cooled to 80.degree. C., and reacted with 170
parts of isophorone diisocyanate in ethyl acetate for 2 hours to
give an isocyanate-having prepolymer (3) having a weight-average
molecular weight of 12,000.
[0296] Preparation of Ketimine Compound
[0297] 30 parts of isophoronediamine and 70 parts of methyl ethyl
ketone were put into a reactor equipped with a stirring rod and a
thermometer, and reacted therein at 50.degree. C. for 5 hours to
give a ketimine compound (1).
[0298] Production of Toner
[0299] 15.4 parts of the prepolymer (3), 50 parts of the polyester
(a) and 95.2 parts of ethyl acetate were put into a beaker, and
dissolved by stirring them. Next, 20 parts of carnauba wax
(molecular weight 1800, acid value 2.5, needle penetration 1.5
mm/50.degree. C.) and 3 pars of copper phthalocyanine blue pigment
were added thereto and uniformly dissolved and dispersed by
stirring them at 85.degree. C. with a TK-type homomixer at 12,000
rpm. Fishy, 2.7 parts of the ketimine compound (1) was added
thereto and dissolved. This is a toner material solution (1). On
the other hand, 865 parts of ion-exchanged water, 245 parts of 10%
hydroxyapatite suspension Nippon Chemical Industry's Supertite 10),
and 0.4 parts of sodium dodecylbenzenesulfonate were put into a
beaker and uniformly dissolved. Next, this was heated up to
60.degree. C., and with stirring it with a TK-type homomixer at
12,000 rpm, the toner material solution (1) was added thereto, and
stirred for 10 minutes. The resulting mixture was transferred into
a flask equipped with a sing rod and a thermometer, and heated up
to 60.degree. C. for urea formation for 2 hours with removing the
solvent This was filtered, washed and dried, and then pneumatically
classified to obtain toner particles having a weight-average
particle diameter of 7 .mu.m. Next, 100 parts of the toner
particles were mixed with 0.3 parts of hydrophobic silica and 0.3
parts of hydrophobic titanium oxide using a Henschel mixer to
obtain a toner (14) of the present invention. Its test data are
given in Table 2.
Comparative Example 1
[0300] Preparation of Toner Binder
[0301] 395 parts of bisphenol A-ethylene oxide (2 mols) adduct and
166 parts of isophthalic acid were polycondensed in the presence of
2 parts of a catalyst dibutyltin oxide to give a comparative toner
binder (x) having a weight-average molecular weight of 8000. Tg of
the comparative toner binder (x) was 57.degree. C.
[0302] Production of Toner
[0303] 100 parts of the comparative toner binder (x), 180 parts of
ethyl acetate, 4 parts of copper phthalocyanine blue pigment, and 5
parts of rice wax (m.p. 82.degree. C., needle penetration 9 at
50.degree. C.) were put into a beaker and uniformly dissolved and
dispersed by sing them at 50.degree. C. with a TK-type homomixer at
10,000 rpm. Next, this was processed in the same manner as in
Example 1 to produce toner, for which, however, the toner material
mixture was stirred more strongly to remove the solvent and the
solvent removal took 8 hours. The comparative toner (1) thus
produced had a true-spherical particle morphology having a
weight-average particle diameter of 6 .mu.m. The main peak
molecular weight Mp of the binder resin in the toner was 5000; the
content of molecules having Mw of 30,000 or more in the binder
resin was 0.3%; and Mw/Ma of the binder resin was 2. The test data
of the comparative toner (1) are given in Table 2.
Comparative Example 2
[0304] Preparation of Toner Binder
[0305] 343 parts of bisphenol A-ethylene oxide (2 mols) adduct 166
parts of isophthalic acid and 2 parts of dibutyltin oxide were put
into a reactor equipped with a condenser tube, a stirrer and a
nitrogen-introducing duct, and reacted therein for 8 hours at
230.degree. C. under atmospheric pressure, and then for 5 hours
under a reduced pressure of 10 to 15 mmHg. After this was cooled to
80.degree. C., 14 parts of toluene diisocyanate was added thereto
in toluene, and reacted with it at 110.degree. C. for 5 hours. The
solvent was removed to give an urethane-modified polyester (1)
having a weight-average molecular weight of 98,000. On the other
hand, 363 parts of bisphenol A-ethylene oxide (2 mols) adduct and
166 parts of isophthalic acid were polycondensed in the same manner
as in Example 1 to give a non-modified polyester (j) having a peak
molecular weight of 3800, a hydroxyl value of 25 and an acid value
of 7. 350 parts of the urethane-modified polyester and 650 parts of
the non-modified polyester were dissolved in toluene by mixing
them, and the solvent was removed to give a comparative toner
binder (y). Tg of the comparative toner binder (y) was 58.degree.
C.
[0306] Production of Toner
[0307] 100 parts of the comparative toner binder (y), 4 parts of
copper phthalocyanine blue pigment, and 10 parts of candelilla wax
(m.p. 69.degree. C., needle penetration 5.8, Mw 900, acid value 16)
were processed to form a toner according to the method mentioned
below. Concretely, these were premixed in a Henschel mixer, and
then kneaded in a continuous kneader. Next, this was ground in a
jet mill, and then classified in a pneumatic classifier to obtain
toner particles having a weight-average particle diameter of 6
.mu.m. Next, 100 parts of the toner particles were mixed with 0.5
parts of hydrophobic silica and 0.5 parts of hydrophobic titanium
oxide in a Henschel mixer to give a comparative toner (2). The main
peak molecular weight Mp of the binder resin in the toner was 3800;
the content of molecules having Mw of 30,000 or more in the binder
resin was 15%; and Mw/Mn of the binder resin was 6. The test data
of the comparative toner (2) are given in Table 2.
[0308] Test Methods:
[0309] Using a powder tester from Hosokawa Micron, the bulk density
of toner was measured. Toner of better flowability has higher bulk
density. Thus tested, toner was ranked as follows:
[0310] D: lower than 0.25.
[0311] C: 0.25 to 0.30.
[0312] B: 0.30 to 0.35.
[0313] A: higher than 0.35.
[0314] Thermal Storability:
[0315] After kept at 50.degree. C. for 8 hours, the toner was
sieved through a 42-mesh sieve for 2 minutes, and the residue on
the sieve was measured. This indicates the thermal storability of
toner. Toner of better thermal storability gives a smaller amount
of residue on the sieve in the test. Thus tested, toner was ranked
as follows:
[0316] D: more than 30%.
[0317] C: 20 to 30%.
[0318] B: 10 to 20%.
[0319] A: less than 10%.
[0320] Lowermost Temperature for Toner Fixing:
[0321] A Ricoh's copier MF-2000 having a fixing roller of Teflon is
modified in the fixing zone, and Ricoh's copy paper of type 6200 is
set in the modified copier, in which toner is tested for image
forming on the copy paper. The image fixed on the copy paper was
rubbed with a pad, and the image retention thereon was measured.
The temperature of the fixing roller at which the image fixed on
the copy paper had an image-retention of 70% or more indicates the
lowermost temperature for toner fixing.
[0322] Hot Offsetting Temperature (HOT):
[0323] The image fixed on the copy paper in the same manner as in
the test for toner fixing as above was visually checked for hot
offsetting. The temperature of the fixing roller at which the paper
with an image fixed thereon had suffered hot-offsetting indicates
the hot-offsetting temperature of toner.
[0324] Gloss-Expressing Temperature (GLOSS):
[0325] The toner is tested in the fixing unit of a commercial color
copier, Ricoh's PRETER 550. The temperature of the fixing roller at
which the 60-degree gloss of the fixed image was 10% or more
indicates the gloss-expressing temperature of toner.
[0326] Test Results:
[0327] The toners of the present invention produced in Examples 1
to 14 and the comparative toners 1 and 2 were tested in a
laboratory copier having a belt fixing unit of FIG. 1 and FIG.
2.
[0328] In addition, the comparative toners 1 and 2 were tested in a
different laboratory copier having a roller fixing unit of FIG.
3.
[0329] The test condition in the belt fixing unit is as
follows:
[0330] As in FIGS. 1 and 2 showing the conceptual views thereof,
the belt fixing unit used herein comprises a fixing roller 2, a
heating roller 1, an endless fixing belt 3 laid along the heating
roller 1 and the fixing roller 2 under tension therebetween, a
pressure roller 4 disposed adjacent to the fixing roller 2 via the
fixing belt 3, and a fixing heater 5 disposed inside the heating
roller 1; A toner image on transfer paper, a type of transfer
material that is conveyed between the pressure roller 4 and the
fixing belt 3 is fixed thereon in this unit. The unit is so
controlled that, in the step for fixing in the part 8 in which the
pressure roller 4 is kept in contact with the fixing belt 3 not
pressing the fixing roller 2 via the fixing belt 3, the fixing
pressure to the transfer paper is settled low so as not to wrinkle
the transfer paper, and in the second step for fixing in the part 9
in which the pressure roller 4 presses the fixing roller 2 via the
fixing belt 3, the fixing pressure to the transfer paper is settled
to ensure the intended toner fixing on the transfer paper.
[0331] In the step for fixing, the toner on the transfer paper is
prefixed thereon through thermal conduction and the fixing pressure
is kept low so as not to wrinkle the transfer paper. For this, it
is desirable that the fixing belt 3 is lightly contacted with the
pressure roller 4.
[0332] The fixing pressure is described in relation to the wrinkle
resistance of transfer paper, a type of transfer material for toner
fixing thereon. For a fixing pressure of 1 kg/cm.sup.2 in the belt
fixing unit as herein, for example, the tension of the fixing belt
3 is 9 kg, the width of the fixing belt 3 is 310 mm and the contact
length of the fixing belt 3 is 3 mm. In this case, 9 kg/(31
cm.times.0.3 cm).apprxeq.1 kg/cm.sup.2. For a fixing pressure of
0.5 kg/cm2, for example, 4.5 kg/(31 cm.times.0.3 cm).apprxeq.0.5
kg/cm.sup.2. Transfer paper having run through the belt fixing unit
is checked for wrinkles, and ranked as follows: Rank 3 and higher
will not receive users' complaints. Precisely, rank 5 means no
wrinkles formed; rank 4 means a few and negligible wrinkles formed;
rank 3 means some but negligible wrinkles formed, which will not
receive users' complaints; rank 2 means some but nonnegligible
wrinkles formed, which will receive users' complaints; and rank 1
means many and remarkable wrinkles formed.
[0333] In this test, all the toners of Examples 1 to 14 were tested
under a fixing pressure of 1 kg/cm.sup.2, under which all sheets of
transfer paper tested for these toners were on the level of rank 4
or higher.
1 TABLE 1 Composition (Modified Polyester or Preparation of
Component Polyester/ having Component Non- Mw of having Mw THF
modifide 30,000 or of 1000 or Insolubles Acid Tg Binder used
polyester) Mp more (%) Mn Mw/Mn less (%) (%) Value (.degree. C.)
Ex. 1 Non-modified Polyester (a) + 10/90 4000 4 2500 3.5 4 5 7 60
Urea Modified Polyester (1) Ex. 2 Non-modified Polyester (a) +
20/80 4000 5 4000 3.8 4 3 7 64 Urea Modified Polyester (2) Ex. 3
Non-modified Polyester (a) + 3/97 4000 2 2500 4.1 3 3 7 62 Urea
Modified Polyester (3) Ex. 4 Non-modified Polyester (a) + 50/50
4000 6 4000 3.6 4 6 7 61 Urea Modified Polyester (4) Ex. 5
Non-modified Polyester (b) + 10/90 4000 7 4500 4.1 2 4 0.5 61 Urea
Modified Polyester (1) Ex. 6 Non-modified Polyester (c) + 10/90
4000 7 2300 3.5 2 1 2 61 Urea Modified Polyester (1) Ex. 7
Non-modified Polyester (d) + 10/90 4000 7 4100 3.4 3 4 8 69 Urea
Modified Polyester (1) Ex. 8 Non-modified Polyester (e) + 10/90
15000 6 15000 4.6 1 8 25 62 Urea Modified Polyester (1) Ex. 9
Non-modified Polyester (f) + 10/90 1000 4 2300 2.9 4 2 8 45 Urea
Modified Polyester (1) Ex. 10 Non-modified Polyester (l) + 10/90
20000 7 12000 4.2 1 7 8 73 Urea Modified Polyester (1) Ex. 11
Non-modified Polyester (a) + 10/90 4000 5 4200 4.3 3 3 8 62 Urea
Modified Polyester (1) Ex. 12 Non-modified Polyester (a) + 15.4/60
4000 5 3500 3.5 2 2 8 62 Preparation of Polyester (2) Ex. 13
Non-modified Polyester (a) + 15.4/60 4000 5 3100 3.8 5 2 8 62
Preparation of Polyester (2) Ex. 14 Non-modified Polyester (a) +
15.4/50 4000 6 5200 2.8 4 3 8 62 Preparation of Polyester (3) Comp.
Ex. 1 Non-modified Polyester (x) -- 5000 0.3 4200 3.5 3 0 5 57
Comp. Ex. 2 Non-modified Polyester (j) + 35/65 3800 12 2500 4.2 5 0
0.5 60 Urethane Modified Polyester
[0334]
2 TABLE 2 Belt Fixing Unit Roller Fixing Unit Lower- Lower- most
most Weight- Temper- Tempera- ave ature ture rage for for particle
toner Charge Thermal Toner toner Item diameter Roundness fixing
GLOSS HOT Stability Haze Storability Flow fixing GLOSS HOT Unit
.mu.m -- .degree. C. .degree. C. .degree. C. -- -- -- -- .degree.
C. .degree. C. .degree. C. -- Ex. 1 6.0 0.96 140 150 220 B B B B --
-- -- -- Ex. 2 6.9 0.98 140 150 225 B B B B -- -- -- -- Ex. 3 6.0
0.98 135 145 200 B B C B -- -- -- -- Ex. 4 6.2 0.97 145 160 210 B A
B B -- -- -- -- Ex. 5 8.2 0.97 145 150 220 B B B B -- -- -- -- Ex.
6 6.9 0.97 140 150 220 B B B B -- -- -- -- Ex. 7 7.2 0.96 140 150
220 B B B B -- -- -- -- Ex. 8 7.5 0.98 135 150 220 B B B B -- -- --
-- Ex. 9 8.1 0.96 130 140 200 B A B B -- -- -- -- Ex. 10 5.2 0.98
160 170 230 B C B A -- -- -- -- Ex. 11 6.8 0.98 140 160 200 B A B B
-- -- -- -- Ex. 12 7.5 0.97 150 150 230 B B B B -- -- -- -- Ex. 13
5.9 0.96 140 150 220 B B B B -- -- -- -- Ex. 14 4.8 0.97 140 150
220 B B B B -- -- -- -- Co. Ex. 6.8 0.98 140 145 170 C D C D 140
145 185 C 1 Co. Ex. 7.2 0.93 140 150 200 C D B B 140 150 210 B 2
Roller Fixing
* * * * *